Flo-Cal
Online Calorimeter
User Guide
P/N 90-1208-0
Revision K
Part of Thermo Fisher Scientific
Flo-Cal
Online Calorimeter
User Guide
P/N 90-1208-0
Revision K
Document Label Definitions
Symbol
Label
Description
WARNING:
Consists of conditions, practices, or
procedures that must be observed to
prevent personal injury.
CAUTION:
Consists of conditions, practices, or
procedures that must be observed to
prevent injury or equipment damage.
CAUTION:
Risk of electric shock or high
temperature parts may result in injury
if proper precautions are not taken.
CAUTION:
Static Sensitive component.
Appropriate handling required to
prevent damage.
NOTE:
Emphasizes important or essential
information.
Please refer to Chapter 1 (page 1) for important safety
information and instructions on how to use this manual.
Flo-Cal On-Line Calorimeter User Guide
© 2007 Thermo Fisher Scientific. All rights reserved.
Revision date October 2007 – Rev K
Part number 90-1208-0
All terms mentioned in this manual that are known to be trademarks have been
appropriately capitalized. Thermo Fisher acknowledges all trademarks and the rights
of the trademarks owned by the companies referred to herein.
Thermo Fisher Scientific (Thermo Fisher) makes every effort to ensure the accuracy
and completeness of this manual. However, we cannot be responsible for errors,
omissions, or any loss of data as the result of errors or omissions. Thermo Fisher
reserves the right to make changes to the manual or improvements to the product at
any time without notice.
The material in the manual is proprietary and cannot be reproduced in any form
without express written consent from Thermo Fisher.
This page intentionally left blank.
Table of Contents i
Table of Contents
List of Illustrations------------------------------------------------------------- v
Chapter 1-------------------------------------------------------------------------- 1
How to Use This Manual ................................................................................. 1
Safety Considerations ........................................................................................1
Locating Information .........................................................................................2
Instructions and Procedures ...............................................................................3
General Safety and Operating Information........................................................3
Chapter 2-------------------------------------------------------------------------- 7
Specifications .................................................................................................. 7
Results may vary under different operating conditions. ....................................7
Chapter 3-------------------------------------------------------------------------- 11
Introduction ..................................................................................................... 11
Description.........................................................................................................11
Applications .......................................................................................................11
Modes of Operation ...........................................................................................12
Theory of Operation ..........................................................................................12
Standard Operation, Wobbe Index........................................................12
Calorific Value Instruments..................................................................14
Pressure Transmitter ..........................................................................................14
Safety Features...................................................................................................15
Low Inlet Air Pressure..........................................................................15
Low Inlet Gas Pressure .........................................................................15
Flame-Out Detection and Relight .........................................................15
Overrange Detection .............................................................................15
System Options ..................................................................................................15
Flo-Cal User Guide
ii
Table of Contents
Chapter 4 --------------------------------------------------------------------------17
Installation ....................................................................................................... 17
System Mounting .............................................................................................. 17
Unpacking and Inspection .................................................................... 17
Wall Mount Preparation and Procedure ............................................... 18
Free Standing Mount Instructions ........................................................ 20
Electrical Installation......................................................................................... 20
Gas & Air Supply Installation ........................................................................... 22
Chapter 5 --------------------------------------------------------------------------23
Star t Up & Shut Down .................................................................................... 23
Start Up Procedure ............................................................................................ 23
Initial Start Up ...................................................................................... 23
Start Up ................................................................................................ 24
Shut Down Procedures ...................................................................................... 25
Manual Shutdown ................................................................................ 25
Chapter 6 --------------------------------------------------------------------------27
Maintenance .................................................................................................... 27
Maintenance Schedule....................................................................................... 27
Daily ..................................................................................................... 27
Weekly ................................................................................................. 27
Monthly ................................................................................................ 27
Yearly ................................................................................................... 27
After Major Maintenance ..................................................................... 27
Maintenance Procedures.................................................................................... 28
Flame Primary Air Adjustment ............................................................ 28
Relighting the Flame ............................................................................ 28
Pressure Measurement.......................................................................... 29
Inlet Air Pressure Adjustment .............................................................. 30
Inlet Gas Pressure Adjustment ............................................................. 31
Switch Test and Adjustment................................................................. 31
Flame-Out Timer Settings .................................................................... 33
Precision Gas Regulator Diaphragm Replacement .............................. 33
Air Control Valve Diaphragm Replacement ........................................ 33
Measurement Range Change................................................................ 34
Constant Volume (CV) Pump .............................................................. 35
Flo-Cal User Guide
Table of Contents iii
Chapter 7-------------------------------------------------------------------------- 41
Calibration........................................................................................................ 41
Calibration Gases...............................................................................................41
Output Signal Calculation.....................................................................41
Manual Calibration Procedures .........................................................................42
Calibration Verification ........................................................................42
Full Calibration.....................................................................................43
Automatic Calibration........................................................................................44
Specific Gravity Calibration ..............................................................................45
Chapter 8-------------------------------------------------------------------------- 47
Transmitter....................................................................................................... 47
Description.........................................................................................................47
Operation ...........................................................................................................47
System Configuration Procedures ........................................................47
Entering Variables Using the Magnetic Keypad ..................................47
Setup Screen Descriptions .................................................................................52
Cal Mode ..............................................................................................52
Supervisor System Lock .......................................................................53
Alarm Relay Acknowledge Feature......................................................53
Measurement Description and Engineering Units ................................54
Module Range.......................................................................................54
Activating Linearization .......................................................................55
Alarm 1 Setup .......................................................................................56
Alarm 2 Setup .......................................................................................57
Fault / Alarm 3 Setup............................................................................57
Zero Value ............................................................................................58
Span Value............................................................................................58
Unity Gain Setup ..................................................................................58
Serial Port Setup ...................................................................................59
System Hardware...............................................................................................59
CPU Board............................................................................................59
Memory Board......................................................................................60
Display Board .......................................................................................60
Input/Output Board...............................................................................60
RS-232 / RS-485 Configuration ........................................................................60
Terminal Block Connections .............................................................................61
Chapter 9-------------------------------------------------------------------------- 63
Getting Help ..................................................................................................... 63
Additional Information ......................................................................................63
Getting Help.......................................................................................................63
Flo-Cal User Guide
iv
Table of Contents
Chapter 10-------------------------------------------------------------------------65
Glossary .......................................................................................................... 65
Appendix A -----------------------------------------------------------------------69
Flame-Out & Overrange.................................................................................. 69
Flame-Out System............................................................................................. 69
Overrange system .............................................................................................. 70
Appendix B -----------------------------------------------------------------------73
Pressure Conversion Charts.......................................................................... 73
Appendix C -----------------------------------------------------------------------77
Modbus ............................................................................................................ 77
Appendix D -----------------------------------------------------------------------79
Toxic & Hazardous Substances Tables*....................................................... 79
Index --------------------------------------------------------------------------------83
Flo-Cal User Guide
Table of Contents v
List of Illustrations
Figure 1. Symbols used to indicate potential hazards. ................................................................................... 2
Figure 2. Flo-Cal functional diagram. ......................................................................................................... 13
Figure 3. Typical component and adjustment locations. .............................................................................. 30
Figure 4. Pressure transducer board with resistor location......................................................................... 34
Figure 5. CV pump base. .............................................................................................................................. 36
Figure 6. CV pump head, exploded view. ..................................................................................................... 37
Figure 7. Flo-Cal transmitter front panel with NORM display. ................................................................... 48
Figure 8. Setup Mode display. ...................................................................................................................... 49
Figure 9. Menu flow chart. ........................................................................................................................... 50
Figure 10. Cal mode flow chart. ................................................................................................................... 52
Figure 11. Authorization screen. .................................................................................................................. 53
Figure 12. Alarm 2 relay acknowledge feature screen. ................................................................................ 53
Figure 13. Measurement description. ........................................................................................................... 54
Figure 14. Module zero and span. ................................................................................................................ 54
Figure 15. Display linear table screen. ........................................................................................................ 55
Figure 16. Linear table flow chart................................................................................................................ 56
Figure 17. Alarm 1 parameters..................................................................................................................... 56
Figure 18. Alarm 2 parameters..................................................................................................................... 57
Figure 19. Fault or Alarm 3 parameters. ..................................................................................................... 57
Figure 20. Zero value.................................................................................................................................... 58
Figure 21. Span value. .................................................................................................................................. 58
Figure 22. Unity Gain function..................................................................................................................... 58
Figure 23. Modbus serial port configuration. .............................................................................................. 59
Figure 24. Electronic schematic of the Flo-Cal Flame-out and Over-range circuits................................... 71
Figure 25. Toxic & Hazardous Substances Tables – Flo-Cal (ATEX)..........................................................80
Figure 26. Toxic & Hazardous Substances Tables – Flo-Cal (Safe Area)...................................................81
Flo-Cal User Guide
vi
Table of Contents
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Flo-Cal User Guide
How To Use This Manual 1
Chapter 1
How to Use This Manual
This chapter includes important information that must be read and understood by all persons
installing, using, or maintaining this equipment.
Safety Considerations
WARNING: Failure to follow appropriate safety procedures or inappropriate
use of the equipment described in this manual can lead to equipment damage
or injury to personnel.
Any person working with or on the equipment described in this manual is required to
evaluate all functions and operations for potential safety hazards before commencing
work. Appropriate precautions must be taken as necessary to prevent potential damage to
equipment or injury to personnel.
The information in this manual is designed to aid personnel in the correct and safe
installation, operation, and maintenance of the systems described. However, personnel must
consider all actions and procedures for potential hazards or conditions that may not have been
anticipated in the written procedures. If a procedure cannot be performed safely, it must not
be performed until appropriate actions can be taken to ensure the safety of equipment and
personnel. The procedures in this manual are not designed to replace or supersede required or
common sense safety practices. All safety warnings listed in any documents applicable to
equipment and parts used in or with the system described in this manual must be read and
heeded before commencing work on any part of the system.
Failure to correctly perform the instructions and procedures in this manual or other
documents pertaining to this system can result in equipment malfunction, equipment
damage, and injury to personnel.
Flo-Cal User Guide
2
How To Use This Manual
The following symbols are used throughout this manual to alert users to potential hazards or
important information. Failure to heed the warnings and cautions listed herein can lead to
injury and equipment damage.
Document Label Definitions
Symbol
Label
Description
WARNING:
Consists of conditions, practices, or
procedures that must be observed to
prevent personal injury.
CAUTION:
Consists of conditions, practices, or
procedures that must be observed to
prevent injury or equipment damage.
CAUTION:
Risk of electric shock or high
temperature parts may result in injury
if proper precautions are not taken.
CAUTION:
Static Sensitive component.
Appropriate handling required to
prevent damage.
NOTE:
Emphasizes important or essential
information.
Figure 1. Symbols used to indicate potential hazards.
Locating Information
NOTE: In the interest of completeness, manuals and drawings included with the
system may provide information pertaining to options not included with your
system. Information in application notes supersedes general information in these
documents.
Information can be located in this manual using any of the following aids.
Table of Contents
The Table of Contents (page i) provides information about the overall layout and
organization of this manual. It should be used to locate major categories such as start up
information and maintenance requirements.
List of Illustrations
The List of Illustrations (page v) should be consulted to locate drawings or other figures
included in this manual.
Flo-Cal User Guide
How To Use This Manual 3
Index
The Index (page 83) should be used for locating detailed information.
Getting Help
For information on how to contact Thermo Fisher service personnel by telephone, fax, or the
internet, see the Getting Help chapter (page 63).
Glossary
The Glossary chapter provides general definitions for many of the technical terms used in this
manual (see page 65).
Appendix
Appendices are included to provide detailed or supporting information related to the
equipment described in this manual. The appendices can be found after the Getting Help
chapter in this manual.
Instructions and Procedures
This manual makes extensive use of step-by-step instructions and procedures. The listed
functions should be performed in the order shown to ensure proper functioning of the
equipment. Particular attention must be paid to any safety warnings or cautions that may be
listed.
WARNING: Deviation from the specified instruction or procedure steps may
result in equipment malfunction, equipment damage, or injury to personnel.
General Safety and Operating Information
This section contains general safety and operating information applicable to analyzers and
sample systems. This information must be understood by all persons installing, using, or
maintaining the analyzer or sample system. This information is designed to aid personnel in
safe installation, operation, and service of the analyzer and sample systems. It is not designed
to replace or limit appropriate safety measures applicable to work performed by personnel.
Any additional safety and operating measures that are required must be determined by and
followed by personnel performing work on the system.
WARNING: Failure to heed the following information may lead to equipment
damage or injury to personnel.
Flo-Cal User Guide
4
How To Use This Manual
General Precautions
Protective eyewear (glasses with side shields or goggles as appropriate) must be worn when
servicing any part of the analyzer or sample system. When servicing the sample system,
chemical resistant gloves appropriate for the materials in the system must be worn. When
servicing the hot analyzer components (e.g., burner), or hot sample system components,
appropriate gloves must be worn. Heated components should be allowed to cool before
servicing if possible. Other appropriate equipment or clothing must be used as required by the
type of work performed.
WARNING: Ovens, internal components, and sample system components may
be hot even when power is not applied to the unit. Take appropriate precautions
to prevent injury from contact with hot items.
All applicable regulations and procedures must be followed for the work performed. Before
beginning any work on the system, carefully consider all the potential hazards and ensure that
appropriate measures are taken to prevent injury to personnel or equipment damage.
Electrical Power
The system uses AC power at 115 or 230 volts. The AC power is converted to DC at several
voltage levels including high voltage for the sparking unit. Appropriate precautions must be
taken to prevent sparks that may ignite combustible materials that may be present in the
analyzer environment. Precautions must also be taken to prevent electrical shock if the
analyzer or sample system enclosures are opened.
The AC power to the system must be free from noise, surges, sags, and spikes for proper
operation of the system. AC power circuit breakers and wiring must be sized properly for the
required current. All wiring installations must meet applicable electrical codes.
System Location
The analyzer and sample system must be installed in a suitable location. The system must not
be installed in an area classification for which it is not rated. The equipment must be
protected from temperature and humidity extremes. The analyzer must not be mounted in an
area with potentially corrosive atmosphere or high vibration. The system components must be
attached securely and appropriately to a floor or wall. The system must be mounted to permit
adequate access for operation and maintenance.
Flo-Cal User Guide
How To Use This Manual 5
Bottle Gas
WARNING: Flo-Cal applications may use bottled gases. These bottles may
have very high pressures and may result in serious injury to personnel if the
bottle valve is opened without a regulator attached or if the valve is broken off
the bottle. See the following paragraphs for more information.
WARNING: Flo-Cal sample and calibration gases are highly combustible.
Sample or calibration gas leaks in confined spaces can lead to explosive
concentrations. Appropriate precautions must be taken to ensure the safety of
personnel.
The Flo-Cal system may use one or more bottle gases. The bottle gases may contain very
high pressure. Severe injury to personnel and equipment can occur if the bottle gas valve is
damaged or opened without installing an appropriate regulator. A protective cap must be in
place over the bottle valve any time the bottle is moved. Do not move a bottle with the
regulator attached or if the protective cap is missing. Bottles must be securely chained in
place at all times when the protective cap is removed.
Gas type and locations must be clearly marked to prevent connecting the wrong gas type to
the system. Bottles with combustible gases must not be installed in confined areas.
Appropriate measures must be taken to ensure that explosive mixtures are not produced in
case of bottle gas leaks.
Air for fueling the flames must be free from hydrocarbons, moisture, or other contaminants to
prevent noisy operation, inaccurate readings, or other problems.
Sample and Calibration Standard
The measured sample and calibration standard are flammable and may be otherwise
hazardous to humans or the environment. Appropriate precautions must be taken to avoid
ignition of the sample, exposure of personnel, or environmental contamination. Sample and
calibration standard is typically pressurized. Special precautions must be taken any time the
sample or calibration systems must be opened for service to ensure that all pressure is
removed from the system and that hazardous material is removed.
Sample and calibration standard must be representative of actual conditions. Process sample
must be delivered to the analyzer in a timely manner while ensuring that component
concentrations are not modified by sample conditioning. Lag times must be small enough to
ensure a fresh sample for analysis.
Flo-Cal User Guide
6
How To Use This Manual
Filters
Filters may be used to reduce sample system maintenance requirements by removing
particulate material from the sample. Periodically, filters must be replaced or cleaned. All
pressure must be removed from the filter before servicing. The filter and associated sample
system must be decontaminated appropriately before removal or service. Used filters or filter
elements must be disposed in compliance with all applicable regulations for the potential
materials filtered and the material from which the filter was constructed. Replacement filters
or elements must be of the correct porosity and material for the application.
Valves
Valves must be properly labeled to prevent incorrect alignment. Valves can leak through or
leak out. When opening the sample system, precautions must be taken to prevent injury to
personnel or damage to equipment in the event that a valve leaks or is misaligned.
Before removing or disconnecting any valve, hazardous materials must be thoroughly
removed from the valve internals and all pressure must be relieved. When installing a new or
serviced valve, all fittings and surfaces must be checked for leaks.
Vents
Vents are used to expel the spent gases from the analyzer system. The vents must be routed to
a safe location as necessary to prevent injury to personnel. Backpressure on vents must be
kept to an absolute minimum to prevent degrading system performance. Long vent runs must
be avoided. Precautions must be taken to ensure that condensate cannot accumulate in vent
lines.
Flo-Cal User Guide
Specifications 7
Chapter 2
Specifications
Results may vary under different operating conditions.
Features
Fast response for Wobbe Index and
Calorific Value measurements
Specific Gravity measurement
(optional on Calorific Value instruments only)
High reliability and low maintenance
Modbus® protocol
Menu driven parameter entry
Non-intrusive magnetic keypad
Remote Windows® workstation option
Dual level alarms
4 - 20 mA analog output
Enhanced accuracy with optional
microprocessor Auto-Calibration
Auto switching capabilities for
external sample calibration checks
Flame safety automatic interlock
Flo-Cal User Guide
8
Specifications
Hardware Specifications
Dimensions
42" H, 22" W, 14.5" D (1.07m H, 0.56m W,
0.37m D), general purpose unit (Model 7000)
77" H, 38" W, 27" D (1.9m H, 0.95m W,
0.68m D), explosion proof unit (Model 5000)
Weight
Mounting
Ambient Temperature
Area Classification
≈ 150 lbs. (68 kg), general purpose unit
≈ 550 lbs. (250 kg), explosion proof unit
Wall mounting enclosure, standard.
Freestanding rack, freestanding enclosure, or
temperature controlled enclosure, optional.
Temperature controlled ± 15° F. Suitable
enclosures are available as options.
General purpose or
Class 1, Div 1, Group B optional
Process Sample Connection
1/4" tube fittings
Instrument Air Connection
1/2" tube fittings
Power & Signal Inlets
1/2" NPTF (each)
Analytical Specifications
Modes of Operation
Measuring Range
Accuracy
Up to 2500 BTU/SCF (25,000 Kcal/Nm3),
standard, where the upper value is twice the
lower value. Extended range is available
(40 - 100% of scale).
± 1.0% of upper range value, ± 0.5% of upper
range value with optional auto calibration
Repeatability
± 0.3% of upper range value
Linearity
± 0.2% of upper range value
Response Time
Automatic Calibration
Flo-Cal User Guide
Wobbe Index or Calorific value
(BTU/SCF, MJ/Nm3 or Kcal/Nm3)
6-8 seconds plus sample transport time, typical
(Units measuring heat values below about 800
BTU may have longer response time.)
Optionally available
Specifications 9
I/O Specifications
Display
Operator Control
Network Output
Analog Output
Alarm Contacts
Local display for maintenance use:
2-line, 16-character alphanumeric, backlit LCD
Uses non-intrusive magnetic sensors behind the
keypad for operation
2- or 4-wire RS-485 or RS-232, Modbus
protocol
Continuous, isolated 4-20 mA DC, maximum
load of 750 ohms.
Dry contacts, 1 amp @ 30 volts or 0.5 amp @
125 volts resistive loads (standard). (flame out,
over range, and user defined alarms)
Sample Requirements
Flow Rate
500 - 2500 cc/min (depending on gas heating
value). There must be no liquid in the sample.
Use a membrane filter if necessary.
Pressure
For general purpose (Model 7000), 3 - 60 psig
constant pressure (7 - 414 kPa). Consult
Thermo Fisher for other conditions.
For Class I, Div 1 (Model 5000, explosion
proof), the unit’s inlet pressure cannot exceed
5 psig and it cannot work properly with less than
3 psig constant pressure. For fluctuating
pressures less than 3 psig, use of a sample
pump is recommended. Consult Thermo Fisher
for other conditions.
Utility Requirements
AC power
Instrument Air
115 ± 10% VAC, 50/60 Hz @ 5 amps
maximum, standard
220 ± 10% VAC, 50/60 Hz, optional
For the Model 7000, 60 - 125 psig (414 - 862
kPa) @ 2.5 to 6.0 SCFM (71 - 170 l/m)
depending on gas heating value. Air must be
dry and oil free. An optional air blower is
available for general purpose models.
Flo-Cal User Guide
10
Specifications
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Flo-Cal User Guide
Introduction 11
Chapter 3
Introduction
Description
Flo-Cal On-Line Calorimeters are used in feed forward control and high-speed gas blending
operations where continuous measurement of the gas heating value is required. The fast
response, reliable operation, and ease of maintenance and calibration of the Flo-Cal have
made Thermo Fisher the world leader in Wobbe Index and Calorific Value calorimeters.
Recent enhancements to the physical and electronic design of the Flo-Cal have resulted in an
even more stable and versatile instrument. For example, ambient temperature variations have
even less effect on Flo-Cal measurements than before. In addition, the new Modbus output
capabilities make the Flo-Cal easier to integrate into plant control systems.
This manual covers the general purpose Model 7000 and the explosion proof Model 5000.
Applications
Where the fuel gas composition varies, the heating characteristics vary. The Flo-Cal is a
necessary tool to efficiently use the available energy of the fuel gas. Because of its rapid
response and reliability, the Flo-Cal is typically used in the following applications.
· Feed Forward Combustion Control
· Mixing and Blending of Gas Streams
· Gas Quality Monitoring for manual adjustments, cost checking of gas suppliers, and for
burning equipment testing
The industries that have successfully used Flo-Cal calorimeters include the following.
·
·
·
·
·
·
·
·
·
Refining and Petrochemical
Steel Gas Production and Distribution
Coal Gas
Cogen Plants
Fiberglass
Carbon Black
Landfill Gas
Flare Gas
and many other applications
Flo-Cal User Guide
12
Introduction
Modes of Operation
The Flo-Cal has two basic modes or operation: Wobbe Index and Calorific Value. Wobbe
Index provides a meaningful measure of the actual heating characteristics of fuel gas. It is
derived from the basic heat flow equation with Wobbe Index defined as the Calorific Value
divided by the square root of the specific gravity. Wobbe Index measures the combined
effects of fuel gas composition changes.
Calorific Value is the heat value of the gas at standard conditions expressed as Gross Heating
Value or Net Heating Value. Gross Heating Value is the theoretical heat value of the gas at
standard conditions. Net Heating Value is the actual available heat value of the gas at
standard conditions. Net Heating Value is frequently used in calculations to determine the
heat potential for the gas.
Theory of Operation
Standard Operation, Wobbe Index
The Flo-Cal Calorimeter is a high-speed (6 to 8 seconds response) instrument. The variations
in the rate of heat released from a continuously burning gas are fed back via a thermal
expansion element to a flapper-nozzle control system, which adjusts the flow of cooling air to
the air orifice and subsequently the burning chamber. The varying flow of air is used to
control the temperature of the combustion products. This yields an air flow rate that varies
according to the heat released by the gas. Measuring the airflow provides a direct
measurement of the heat value of the burning gas.
A continuous stream of gas enters a precision gas regulator in the Flo-Cal calorimeter. This
precision gas regulator controls the pressure of the gas flowing into the calibrated gas orifice
of the burner.
Air is delivered to the air control valve by either a blower or an air regulator supplied by an
instrument air source. The air control valve regulates the flow of air through the air orifice to
the burner. Part of the air supplied to the burner is mixed with the gas for combustion while
the remainder serves as a heat exchange medium around the burning chamber.
A safety shutdown system prevents gas flow to the burner in the event of low air inlet
pressure, or low gas inlet pressure. The air and gas pressure switches are normally open.
When air and gas minimum pressures are reached, the switches close to energize the gas
solenoid valve allowing gas flow to the burner.
A mixing baffle at the top of the burning chamber mixes the heat exchange air with the
products of combustion. The hot mixture passes over a thermal expansion element, the length
of which varies as a direct function of temperature. A freely hinged lever held by a spring in
contract with the thermal expansion element has a vane attached to it at its lower end. The
vane and control jet are called a flapper-nozzle system. The flapper-nozzle system works as
follows.
Flo-Cal User Guide
Introduction 13
The vane restricts the flow of air from the control jet. The latter is fed from the air inlet line
through a restriction orifice. A change in the vane restriction causes a change in the airflow
rate out of the control jet. The backpressure generated by this change results in a load
alteration within the air control valve. An increase in the load on the air control valve
diaphragm causes an increase in the airflow through the valve. The airflow varies to maintain
a constant temperature at the thermal expansion tube. Compensation tubes adjust for
temperature changes in the incoming air, so that the net effect is a constant differential
temperature of the air.
Figure 2. Flo-Cal functional diagram.
The pressure across the air orifice is measured by a differential pressure transducer. The
pressure differential across the air orifice is an indication of a change in flow rate of the air.
This is proportional to the measured heat value within the calibrated range of the Calorimeter.
A meaningful measure of the actual heating characteristics of the sample gas is the Wobbe
Index. The Wobbe Index is derived from the basic heat flow equation and is defined by the
following equation.
Flo-Cal User Guide
14
Introduction
In this equation, Calorific Value is defined as the unit of heat energy per unit standard
volume and can be measured in BTU/SCF, MJ/Nm3, or Kcal/Nm3.
The standard Calorimeter measures the Wobbe Index value of a sample gas. The measured
heat value is output as a 4-20 mA DC signal with an optional Modbus output available.
Alarm outputs are also available.
The Calorimeter has an auto-ignitor to re-light the burner in case of a flame-out. A flame-out
may occur when the system is subjected to power dips or loss of gas or air pressure. This
causes the sample gas heat value to go below the low range of the instrument. The autoignitor will relight the burner and put the instrument back in operation within a few seconds.
The auto-ignitor was designed to operate in conjunction with a protection interlock system
within the calorimeter to ensure positive lighting of the flame and shutdown of the instrument
as the conditions dictate. When a flame-out occurs, the system checks the inlet air and gas
pressure switches. If both pressures are above the minimum, a solenoid valve opens allowing
gas to flow into the burner, and the auto-ignitor sparks to light the flame. The
auto-ignitor stops sparking when the flame-out pressure switch indicates a pressure above
0.6" WC.
Calorific Value Instruments
The Flo-Cal Calorimeter may be configured to measure Calorific Value instead of Wobbe
Index. This configuration includes a constant volume (CV) positive displacement metering
pump on the gas inlet. The Calorimeter measures the net calorific value of the sample gas or,
with a calculated offset, the gross calorific value. As with the Wobbe Index, the Calorific
Value is usually measured in BTU/SCF, MJ/Nm3, or Kcal/Nm3. The calorific value is defined
as the heat value of a gas per unit volume at standard conditions. Unit volume is measured for
30" Hg at 60° F for BTU/SCF measurements and 760 mm Hg at 0° C (i.e., STP) for
Kcal/Nm3 or MJ/Nm3 measurements.
Calorific value is expressed as Gross Heating Value or Net Heating Value. Gross Heating
Value is the theoretical heat value of the sample gas at standard conditions. Net Heating
Value is the actual available heat value of the gas at standard conditions. This is the gross
heating value minus the latent heat of vaporization of the water vapor formed during the
combustion process.
The heating value of the gas being measured is affected by its moisture content. The
calorimeter is typically calibrated for dry gas. It can be calibrated for a saturated gas.
Pressure Transmitter
The Calorimeter uses a programmable low-pressure transmitter for accurate pressure
measurement. The microprocessor-based transmitter monitors the pressure at the air orifice
and produces a continuous 4-20mADC output signal that is proportional to the heat value of
the measured gas. See page 47 for more information on the pressure transmitter.
Flo-Cal User Guide
Introduction 15
Safety Features
The Flo-Cal calorimeter includes several safety features as described in the following
paragraphs.
Low Inlet Air Pressure
If the inlet air pressure drops too low, the calorimeter will shutdown and close a solenoid to
shut off gas flow to the burner. See page 30 for inlet air pressure switch adjustment.
Low Inlet Gas Pressure
If the inlet gas pressure drops too low, the calorimeter will shutdown and close a solenoid to
shut off gas flow to the burner. See page 31 for inlet gas pressure switch adjustment.
Flame-Out Detection and Relight
The pressure of the air entering the burner is monitored. When the burner flame goes out, the
air pressure drops to 0.4" WC. This pressure drop is sensed by the flame-out pressure switch
to initiate attempts to relight the flame. If the sparking unit fails to relight the flame in a few
minutes (see page 33), the calorimeter closes the solenoid valve on the gas inlet, removes
power from the CV pump (if installed), and turns off the sparking ignitor. The instrument
must be reset (with a push-button on non-explosion proof units or by cycling the power to
explosion proof units) before the flame will attempt to relight after a flame-out shutdown. See
the appendix beginning on page 69 for more information on the flame-out system.
Overrange Detection
If the measured heat value exceeds the maximum range of the unit, the system will
automatically extinguish the burner. After five minutes, the system will relight the burner.
Alarm 2 on the transmitter is used to set the overrange value. See the appendix beginning on
page 69 for more information on the overrange detection system.
System Options
Following are some of the options available with the Flo-Cal calorimeter.
•
Constant volume gas pump for Calorific Value measurements
•
Auto-calibration with auto switching sampling system
•
Gas enrichment system for expanded range, low quality gas, or hard to light gas
•
Pumping station for applications with < 3 psig sample gas pressure.
•
Pressure reduction for applications with high sample pressures.
•
Sample conditioning systems
•
CSA approval
•
Specific gravity measurement with typical range of 0.2-0.6 at an accuracy of better than ±
1% of full scale value.
Flo-Cal User Guide
16
Introduction
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Flo-Cal User Guide
Installation 17
Chapter 4
Installation
WARNING: Before attempting to install the Flo-Cal analyzer, review the
material in chapter one in this manual and all safety information in this manual
and all other applicable documents.
WARNING: Applicable permits must be obtained and appropriate precautions
must be taken to prevent possible injury to personnel or equipment damage when
installing the system.
System Mounting
The Flo-Cal is shipped with the Flo-Cal User Guide, application notes, drawings, and
applicable vendor data sheets. Review all of the material prior to installing the instrument. If
you have any questions, please contact your local representative or the factory (see page 63).
Unpacking and Inspection
The Thermo Scientific Flo-Cal is typically packaged in one crate for shipment. Other boxes
may be included in some applications. Open all the boxes carefully. Unpack each box and
check the contents against the packing list found in each box to be sure that all of the parts
are included.
WARNING: The Flo-Cal is large and heavy. Do not attempt to unpack or
move the analyzer without appropriate mechanical or personnel assistance.
Check and tighten all parts inside the instrument as applicable. Although the Flo-Cal was
thoroughly inspected prior to shipment, some parts may loosen during shipment. If any parts
are missing or damaged, contact Thermo Fisher immediately for prompt replacement (see
page 63). If the unit arrives damaged or opened, ensure that a claim is made with the freight
carrier.
Flo-Cal User Guide
18
Installation
Wall Mount Preparation and Procedure
Review the proposed mounting area for suitability. The area should be clean and free from
moisture, dust, excessive drafts and vibrations. Refer to the dimension and connection
drawings provided with the system. Ensure that the proposed mounting location provides the
required clearances for opening enclosure doors and access by personnel. Also ensure that
power, gases, and samples can be routed to the proposed location.
The five major types of wall construction include the following.
•
•
•
•
•
Plaster board with wood studs
Plaster board with aluminum studs
Cinder block
Concrete
Fiberglass
Each type of wall should be treated differently. The proper mounting procedure for each type
of wall is discussed in the following paragraphs.
Plaster Board with Wood Studs
Due to the weight of the Flo-Cal, Thermo Fisher does not recommend mounting to this type
of wall. The freestanding rack should be used.
Plaster Board with Aluminum Studs
Due to the weight of the Flo-Cal, Thermo Fisher does not recommend mounting to this type
of wall. The freestanding rack should be used.
Cinder Block
Wall Rack Mounting
Place the Flo-Cal rack against the wall in an appropriate mounting location. Mark the rack
mounting hole center positions on the wall with a pencil. Remove the rack from the wall.
Drill four holes into the wall with a masonry bit. Insert four molley studs (spring-loaded
nuts), one in each hole. Move the Flo-Cal rack against the wall with the wall mounting
bracket holes aligned with the molley studs. Insert a molley bolt with a flat and lock washer
through the rack into the molley stud. Hand-tighten the bolt. Repeat for the remaining holes.
Tighten the bolts evenly and securely.
Wall Enclosure Mounting
The wall mount preparation for mounting an enclosure requires the horizontal mounting of
two pieces of channel (Uni-Strut P3300 or equivalent) to the wall. The Flo-Cal enclosure will
be mounted to these channels. The channel should be approximately 36" long. For mounting
the channel to the wall, we recommend using a 1/2-13 x 1" long (minimum) bolt with
matching molley stud. For mounting the enclosure to the channel, we recommend using a
3/8-16 x 1" long (minimum) bolt with matching channel nut. All bolts require flat and lock
washers.
Flo-Cal User Guide
Installation 19
Place the two mounting channels against the wall in an appropriate mounting location. Ensure
that the spacing and positioning of the channels will permit proper attachment of the
enclosure. Mark the channel mounting hole center positions on the wall with a pencil.
Remove the channels from the wall. Drill four holes into the wall with a masonry bit (two per
channel). Insert four molley studs (spring-loaded nuts), one in each hole. Mount each channel
to the wall with bolts (with flat and lock washers) inserted into the molley studs. Tighten the
bolts evenly and securely.
Once the Uni-Strut P3300 or equivalent channel has been mounted to the wall, the Flo-Cal
enclosure unit may be mounted. Move the enclosure unit so that it lines up with the channels.
Mark the enclosures top and bottom mounting hole center positions on the channel with a
pencil. Move the enclosure away from the wall and channel. Install suitable channel nuts
aligned with the enclosure mounting hole center positions (the pencil marks). Secure the nuts
in the channel. Position the Flo-Cal enclosure unit so that its mounting holes line up with the
channel nuts. Insert a bolt with a flat and lock washer through one of the mounting holes into
the channel's nut. Hand-tighten the bolt. Repeat this procedure for the remaining three
mounting holes. Tighten the bolts evenly and securely.
Concrete
Wall Rack Mounting
Place the Flo-Cal rack against the wall in an appropriate mounting location. Mark the rack
mounting hole center positions on the wall with a pencil. Remove the rack from the wall.
Drill and mount lag shields into the wall. Move the Flo-Cal rack against the wall with the
wall mounting bracket holes aligned with the lag shields. Insert a lag bolt with a flat and lock
washer into the lag shield and hand tighten the bolt. Repeat for the remaining holes. Tighten
the bolts evenly and securely.
Wall Enclosure Mounting
The wall mount preparation for mounting an enclosure requires the horizontal mounting of
two pieces of channel (Uni-Strut P3300 or equivalent) to the wall. The Flo-Cal enclosure will
be mounted to these channels. The channel should be approximately 36" long. For mounting
the enclosure to the channel, we recommend using a 3/8-16 x 1" long (minimum) bolt with
matching channel nut. All bolts require flat and lock washers.
Place the two mounting channels against the wall in an appropriate mounting location. Ensure
that the spacing and positioning of the channels will permit proper attachment of the
enclosure. Mark the channel mounting hole center positions on the wall with a pencil.
Remove the channels from the wall. Drill and mount lag shields into the wall. Mount each
channel to the wall with lag bolts (with flat and lock washers) inserted into the lag shield.
Tighten the bolts evenly and securely.
Once the Uni-Strut P3300 or equivalent channel has been mounted to the wall, the Flo-Cal
enclosure unit may be mounted. Move the enclosure unit so that it lines up with the channels.
Mark the enclosures top and bottom mounting hole center positions on the channel with a
pencil. Move the enclosure away from the wall and channel. Install suitable channel nuts
aligned with the enclosure mounting hole center positions (the pencil marks). Secure the nuts
in the channel. Position the Flo-Cal enclosure unit so that its mounting holes line up with the
channel nuts. Insert a bolt with a flat and lock washer through one of the mounting holes into
the channel's nut. Hand-tighten the bolt. Repeat this procedure for the remaining three
mounting holes. Tighten the bolts evenly and securely.
Flo-Cal User Guide
20
Installation
Fiberglass
Wall rack mounting
Place the Flo-Cal rack against the wall in an appropriate mounting location. Mark the rack
mounting hole center positions on the wall with a pencil. Remove the rack from the wall.
Drill four holes through the fiberglass wall. Mount the Flo-Cal rack to the fiberglass wall
using a doubler plate and nut on the backside of the wall. Flat and lock washers must be used
at both ends of the bolts. Insert the top bolts first and hand tighten. Repeat for the bottom
bolts. Tighten all the bolts evenly and securely.
Wall enclosure mounting
The wall mount preparation for mounting an enclosure requires the horizontal mounting of
two pieces of channel (Uni-Strut P3300 or equivalent) to the wall. The Flo-Cal enclosure will
be mounted to these channels. The channel should be approximately 36" long. For mounting
the enclosure to the channel, we recommend using a 3/8-16 x 1" long (minimum) bolt with
matching channel nut. All bolts require flat and lock washers.
Place the two mounting channels against the wall in an appropriate mounting location. Ensure
that the spacing and positioning of the channels will permit proper attachment of the
enclosure. Mark the channel mounting hole center positions on the wall with a pencil.
Remove the channels from the wall. Drill four holes through the fiberglass wall. Mount the
channels to the fiberglass Insert the top bolts first and hand tighten. Repeat for the bottom
bolts. Tighten all the bolts evenly and securely.
Once the Uni-Strut P3300 or equivalent channel has been mounted to the wall, the Flo-Cal
enclosure unit may be mounted. Move the enclosure unit so that it lines up with the channels.
Mark the enclosures top and bottom mounting hole center positions on the channel with a
pencil. Move the enclosure away from the wall and channel. Install suitable channel nuts
aligned with the enclosure mounting hole center positions (the pencil marks). Secure the nuts
in the channel. Position the Flo-Cal enclosure unit so that its mounting holes line up with the
channel nuts. Insert a bolt with a flat and lock washer through one of the mounting holes into
the channel's nut. Hand-tighten the bolt. Repeat this procedure for the remaining three
mounting holes. Tighten the bolts evenly and securely.
Free Standing Mount Instructions
The Flo-Cal is often attached to a freestanding rack. This rack should be bolted to the floor.
Review the proposed mounting area for suitability. The area should be clean and free from
moisture, dust, excessive drafts and vibrations. Refer to the dimension and connection
drawings provided with the system. Ensure that the proposed mounting location provides the
required clearances for opening enclosure doors and access by personnel. Also ensure that
power, gases, and samples can be routed to the proposed location.
Install lead anchors or threaded studs in the floor to secure the enclosure at the desired
location. When installing the lag bolts or nuts, use a flat and lock washer for each. Tighten
the bolts or nuts securely.
Flo-Cal User Guide
Installation 21
Electrical Installation
AC Power
AC power to the Flo-Cal is connected by the customer at the analyzer. Power wiring and
circuit breakers must be sized appropriately. Refer to drawings provided with the system for
connection information and power requirements. A suitable power switch should also be
provided by the customer near the system for use by maintenance personnel.
CAUTION: Electrical power must be free of spikes, sags, surges, or electrical
noise.
Analog Output Signal
The Flo-Cal includes a 4-20 mA DC current loop output. Refer to drawings included with the
system for information on connecting the 4-20 mA output signal.
Alarm Signal
The Flo-Cal may include optional digital alarm output signals. Refer to drawings included
with the system for information on connecting alarm devices to these outputs.
Modbus Network
The Flo-Cal includes provisions for connection to a standard Modbus protocol network.
Typically, this is configured to use 4-wire RS-485. Alternately, the Flo-Cal can be configured
to support 2-wire RS-485 or RS-232. Consult the wiring drawings included with the system
for information on the configuration type used and details for wiring connection.
Flo-Cal User Guide
22
Installation
Gas & Air Supply Installation
WARNING: Flo-Cal applications may use bottled gases. These bottles may
have very high pressures and may result in serious injury to personnel if the
bottle valve is opened without a regulator attached or if the valve is broken off
the bottle. See chapter one for more information.
Sample Gas Inlet
Sample gas is typically connected to the system using ¼ inch tubing. Refer to drawings
included with the system for more information on the sample gas connection and
requirements.
Instrument Air
Instrument air is used for burner air. Instrument air must have the following qualities to be
acceptable for use: clean, dry, -40° C dew point, oil free, particles ≤ 5µ, ISA grade
hydrocarbon free. Plant instrument air is typically used if it meets these qualifications. An
optional air blower is available for use where adequate instrument air is not available.
Instrument air is connected to the system using ½ inch tubing. Refer to the drawings and
application notes included with the system for more information on instrument air connection
and requirements.
Flo-Cal User Guide
Start Up & Shut Down 23
Chapter 5
Start Up & Shut Down
Start Up Procedure
One or both of the following procedure must be performed when starting up the Flo-Cal.
WARNING: Before initially starting the system, electrical power wiring must
be checked for correct size and routing. In addition, all sample system plumbing
must be thoroughly tested for leaks.
CAUTION: If the sample may contain liquid, a membrane separator (FD pn 471177-0) must be installed to prevent liquid from getting into the Flo Cal. Liquid
in the sample will damage the instrument.
Initial Start Up
When starting up a new installation or after major service work is performed, the following
start up procedure must be followed. Otherwise, perform the start up procedure on page 24.
1.
2.
3.
4.
Check all power wiring for the following.
a. Proper wire size.
b. Correct breaker size.
c. Proper installation (routing, conduit, seals poured, etc.).
d. Proper system grounding.
Check the sample system as follows
a. Ensure that all trash and contaminants are removed from the tubing (blow out
with air or other suitable utility).
b. Check for proper routing and valve arrangement.
c. Test for leaks at a pressure greater than the highest expected operating pressure
under normal and abnormal conditions.
d. Test for proper valve operation.
e. Ensure that the correct porosity filter elements are installed.
f. Ensure that all relief valves are routed to safe locations.
Ensure that all drains and vents for the analyzer and sample system are routed to
appropriate and safe locations. Analyzer vents cannot tolerate significant
backpressure.
Check instrument air as follows.
a. Ensure that all trash and contaminants are removed from all tubing.
Flo-Cal User Guide
24
Start Up & Shut Down
5.
6.
7.
8.
b. Test the tubing for leaks at a pressure higher than the expected operating
pressure.
c. Ensure that any bottle gases are properly secured and regulated. Relief valves
must be installed downstream of the regulators to prevent damage to tubing or
equipment in case of a bottle regulator failure. Ensure that any relief valves are
routed to safe locations.
d. Check the air for moisture, hydrocarbons, or other contaminants. Ensure that the
air meets the requirements listed in the specifications chapter (page 7).
e. Ensure adequate airflow is available (see specs beginning on page 7).
Ensure that the entire analyzer system installation meets all requirements for the area
in which it is installed (e.g., all equipment rated for the area classification).
Locate the white cardboard box containing an envelope that is mounted securely
inside the enclosure prior to shipment from the factory. Remove the calibration
weight(s) from the envelope.
Remove the clear Plexiglas cover from the top of the precision gas regulator (see
page 30 for location). Two screws hold the cover in place. Place the weight(s) (from
the envelope) on the diaphragm disc. Make sure that they slide easily over the shaft.
Reinstall the cover and tighten the screws.
Start the analyzer system using the following start up procedure only when all of the
above steps are successfully completed.
Start Up
This start up procedure should be used for normal start up of the instrument. If this is the
initial startup or if major service was performed on the system, use the initial startup
procedure (page 23).
WARNING: Before initially starting the Flo-Cal analyzer or if major service
was performed, use the Initial Start Up procedure on page 23.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Open the instrument air inlet valve to allow air to flow into the unit. If a blower is
used instead of instrument air, apply power to the blower.
Adjust the air inlet pressure to 8" WC (see page 30) if necessary.
Open the sample gas inlet valve and allow gas to flow into the unit.
Adjust the gas inlet pressure to 5.5" WC (see page 31) if necessary.
Check all connections for leaks. Shut down the system and correct leaks if found.
Apply power to the instrument.
Ensure that the sparking unit ignites the flame. (The sparking unit may continue to
spark for a few minutes after the flame is ignited.
Check the flame-out pressure switch operation (page 31).
Check the inlet air pressure switch operation (page 31).
Check the inlet gas pressure switch operation (page 32).
Adjust the flame primary air (see page 28).
Allow the unit to stabilize, and then perform calibration verification (see page 42).
If an automatic calibration unit is installed, consult the Auto-Cal User’s Guide for
additional start up information.
Flo-Cal User Guide
Start Up & Shut Down 25
Shut Down Procedures
The Flo-Cal will shut down automatically if a flame-out occurs, if sample gas pressure is lost,
or if inlet air pressure is lost. To manually shut down the system, perform the following steps.
Manual Shutdown
1.
2.
3.
4.
Close the valve supplying sample gas to the Flo-Cal and wait until the flame goes
out.
Close the valve supplying instrument air to the instrument or turn off power to the air
blower as appropriate.
Turn off the main power to the Flo-Cal.
If an automatic calibration unit is installed, consult the Auto-Cal User’s Guide for
additional shutdown information.
WARNING: Pressure must be completely removed from the sample lines before
attempting to open the sample system for any reason.
WARNING: Appropriate precautions must be taken to prevent personnel or
environmental exposure when depressurizing or opening the sample system.
Flo-Cal User Guide
26
Start Up & Shut Down
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Flo-Cal User Guide
Maintenance 27
Chapter 6
Maintenance
This chapter includes basic maintenance information for the system. Additional details can be
found in vendor documents and other manuals provided with the system.
Maintenance Schedule
Following is a suggested maintenance schedule. Specific applications may require additional
maintenance steps or different frequencies.
Daily
1.
2.
Visually inspect the system for leaks.
Check for proper operation of the system.
Weekly
1.
Perform a verification of the system calibration (see page 42).
Monthly
1.
2.
3.
4.
5.
6.
7.
8.
Check all tubing for leaks or damage.
Lubricate the CV pump on Calorific Value instruments (see page 36).
Replace filter elements.
Check the inlet gas pressure (selector valve position 2, see page 29).
Check the delta P pressure (selector valve position 5, see page 29).
Check the inlet air pressure (selector valve position 4, see page 29).
Check the heat value pressure (selector valve position 3, see page 29).
Dust and wipe off the analyzer and associated equipment.
Yearly
1.
Perform a full calibration (see page 43).
After Major Maintenance
1.
2.
3.
4.
5.
6.
Visually inspect the system for leaks.
Check the inlet gas pressure (selector valve position 2, see page 29).
Check the delta P pressure (selector valve position 5, see page 29).
Check the inlet air pressure (selector valve position 4, see page 29).
Check the heat value pressure (selector valve position 3, see page 29).
Perform a full calibration (see page 43).
Flo-Cal User Guide
28
Maintenance
Maintenance Procedures
Flame Primary Air Adjustment
Proper operation of the Flo-Cal instrument requires correct primary burner airflow. Perform
the following to adjust the primary air.
1.
2.
2.
Locate the knob for adjusting the primary airflow at the bottom of the burner.
Determine the type burner installed from the application notes provided with the
instrument. Use the appropriate procedure below to adjust the primary airflow.
a. For burner p.n. 30-1001-0 with ceramic meta jets, adjust the primary air knob so
that the inner flame cone (dark blue) rises and merges with the outer flame cone
(light blue). Then increase the primary airflow by turning the knob ¼ turn
clockwise.
b. For burner p.n. 30-1006-0 with ceramic screen, adjust the primary air knob so
that the inner flame cone (dark blue) rises and merges with the outer flame cone
(light blue). Then increase the primary airflow by turning the knob ¼ turn
clockwise.
c. For burner p.n. 30-1005-0 with glass burner, adjust with a gas that has a heat
value equal to the lowest value expected from the sample gas. Adjust the primary
air knob so that the inner flame cone (dark blue) rises and merges with the outer
flame cone (light blue). Do not increase the primary airflow beyond this point.
As gas with higher heat value is measured, the inner flame cone will separate
from the outer flame cone. This is acceptable.
d. For burner p.n. 30-1003-0 with metal burner, adjust with a gas that has a heat
value equal to the lowest value expected from the sample gas. Adjust the primary
air knob so that the inner flame cone (dark blue) rises and merges with the outer
flame cone (light blue). Do not increase the primary airflow beyond this point.
As gas with higher heat value is measured, the inner flame cone will separate
from the outer flame cone. This is acceptable.
Allow the unit to stabilize after adjusting the primary airflow.
Relighting the Flame
If air or sample pressure is lost, the system gets an overrange alarm, or the flame fails to
relight after flame-out, the Flo-Cal system automatically shuts down. Automatic shut down
closes a solenoid valve to shut off sample gas to the analyzer. The sparking ignitor and
constant volume (CV) pump (Calorific Value units only) are also shut off. To relight the
flame, perform the following.
1.
2.
3.
4.
Determine and correct the cause of the automatic shut down of the Flo-Cal system.
Ensure that instrument air and sample gas are available to the analyzer.
For standard (non-explosion proof) Flo-Cal calorimeters, momentarily depress, then
release the Auto-Ignitor Relay Reset push-button on the front door of the instrument.
Cycle power to an explosion proof Flo-Cal model to reset the system.
If the system fails to restart or if it shuts down again soon after restart, the problem
must be investigated and corrected before attempting to restart the Flo-Cal. Check the
following items.
a. Ensure that the electrode sparks during the relight attempt.
b. Ensure that the electrode sparks are jumping between the electrode points and not
from the electrode point to ground.
Flo-Cal User Guide
Maintenance 29
c. Check all pressure measurements (see the next section) against the normal values
recorded in the application notes or system logbook.
d. Ensure that the weights are properly installed on the precision gas regulator.
e. If these steps fail to isolate the cause, contact Thermo Fisher for assistance (see
page 63).
Pressure Measurement
During normal operation, the measurement selector value is set to position 3 so that the
pressure transmitter measures the heat value of the sample gas. The other selector valve
positions can be used to check other pressures in the Flo-Cal for use in troubleshooting and
calibration. The following chart shows the function and typical pressures for each of the
selector valve positions.
Valve Position
Measured Component
Typical Value
2
Inlet gas pressure
5.5" ± ½" WC
3
Heat Value
(normal operating position)
Depends on
gas and range
4
Inlet air pressure
8" ± ½" WC
5
Delta P,
outlet pressure of CV pump
See application
notes
A temporary range change push-button is provided to momentarily extend the pressure
transmitter’s range when necessary. This momentary push-button is located on the pressure
transducer board inside the Flo-Cal (see page 34). While the push-button is depressed, the
transmitter measures from 0 to 8.3 inches WC. However, the display shows a number that is a
percentage of the module range settings. To determine the actual measured value when the
range push button is depressed, the following formulas can be used. Appendix B (page 73)
also includes cross-reference charts for translating the readings based on the instrument range
used.
To determine the actual measured pressure for a displayed value with the push button
depressed, use the following formula…
To determine the displayed pressure for a desired pressure with the push button depressed,
use the following formula…
Flo-Cal User Guide
30
Maintenance
Figure 3. Typical component and adjustment locations.
Inlet Air Pressure Adjustment
The inlet air pressure is typically controlled by the Inlet Air Pressure Regulator (see above).
Perform the following to set the pressure.
1.
2.
3.
4.
Set the selector valve to position 4 to read the inlet air pressure.
Remove the adjustment cap from the Inlet Air Pressure Regulator.
Adjust the regulator for 8.0 ± 0.5 inches water column while depressing the Test
Point Switch. See appendix B (page 73) for instructions to determine the transmitter
reading that represents 8.0" WC when the Test Point Switch is depressed. The
instrument range can be determined from the application notes provided with the FloCal.
Replace the adjustment cap on the Inlet Air Pressure Regulator.
Flo-Cal User Guide
Maintenance 31
Inlet Gas Pressure Adjustment
The inlet gas (sample) pressure is typically controlled by the Inlet Gas Pressure Regulator
(see above). Perform the following to set the pressure.
1.
2.
3.
4.
Set the selector valve to position 2 to read the inlet gas pressure.
Remove the adjustment cap from the Inlet Gas Pressure Regulator.
Adjust the regulator for 5.5 ± 0.5 inches water column while depressing the Test
Point Switch. See appendix B (page 73) for instructions to determine the transmitter
reading that represents 5.5" WC when the Test Point Switch is depressed. The
instrument range can be determined from the application notes provided with the FloCal.
Replace the adjustment cap on the Inlet Gas Pressure Regulator.
Switch Test and Adjustment
Inlet Air Pressure Switch
The inlet air pressure switch is used to automatically shut down the Flo-Cal if the inlet air
pressure is lost. This switch is set to open at 3.0" WC with decreasing pressure. The
following procedure can be used to test for proper operation.
1.
2.
3.
4.
5.
6.
7.
8.
Mark and disconnect the electrical leads to the inlet air pressure switch (see page 30 for
location).
Connect an ohmmeter to the normally open and common terminals of the pressure
switch.
Open the instrument airline to the instrument.
Set the selector valve to position 4 to monitor the inlet air pressure. Adjust the air inlet
pressure (page 30) to read 3.0" WC.
Adjust the air inlet pressure above and below 3.0" WC while watching the ohmmeter.
The ohmmeter should indicate an open circuit below 3.0" ± 0.05" WC and a closed
circuit above 3.0" ± 0.05" WC.
If the pressure switch does not open at the correct pressure, adjust the small Allen set
screw on the switch and retest.
After the air pressure switch successfully passes the test, adjust the air pressure regulator
for a pressure of 8.0" ± 0.5" WC (for general purpose and Group D instruments). For
area classification Groups B & C, adjust for a pressure of 22.0" ± .5" WC and adjust the
maxitrol for an air inlet pressure of 8.0" ± 0.5" WC. See appendix B (page 73) for
instructions to determine the transmitter reading that represents 5.5" WC when the Test
Point Switch is depressed.
Disconnect the ohmmeter and reconnect the electrical leads to the inlet air pressure
switch.
Flame-Out Pressure Switch
The flame-out pressure switch is used to shut down the Flo-Cal if the flame is extinguished.
This switch is set to close at 0.6" WC with decreasing pressure. (Typically, the pressure with
no flame is 0.4" WC.) Proper operation and adjustment of this switch can be performed with
the following procedure.
1.
2.
Mark and disconnect the electrical leads to the flame-out pressure switch (see page 30
for location).
Connect an ohmmeter to the normally closed and common terminals of the pressure
switch.
Flo-Cal User Guide
32
Maintenance
3.
4.
5.
6.
7.
8.
Rotate the selector valve to position 3 to measure the heat value.
Adjust the air control valve so that the pressure transmitter reads 0.6" WC. The air
control valve adjustment is located on the bottom of the air control valve. Loosen the
lock nut and rotate the adjusting screw clockwise to decrease or counter-clockwise to
increase.
Vary the pressure up and down while watching the ohmmeter and pressure. The
ohmmeter should indicate an open circuit above 0.6" WC and a closed circuit below 0.6"
WC.
If the switch set point is incorrect, remove the switch cover and adjust the switch using
the set point adjustment located at top left of switch. Retest the switch operation after
adjustment.
When the switch is properly set, adjust the air control valve for a pressure reading of
0.4" ± 0.05" WC. (This is the “flame-out air pressure.”)
Disconnect the ohmmeter and reconnect the electrical leads to the flame-out pressure
switch.
Inlet Gas Pressure Switch
The gas pressure switch is used to automatically shut down the Flo-Cal if the sample gas
pressure is lost. The gas pressure switch is set to open at 3.0" WC with decreasing pressure.
Proper operation and adjustment of this switch can be performed with the following
procedure.
1.
2.
3.
4.
5.
6.
7.
8.
Mark and disconnect the electrical leads to the gas pressure switch (see page 30 for
location).
Connect an ohmmeter to the normally open and common terminals of the pressure
switch.
Rotate the selector valve to position 2 to measure the inlet gas pressure.
Adjust the gas pressure regulator (see page 31) for a pressure reading of 3.0" WC.
Vary the pressure up and down while watching the ohmmeter and pressure. The
ohmmeter should indicate a closed circuit above 3.0" WC and an open circuit below
3.0" WC.
If the pressure switch does not open at the correct pressure, adjust the small Allen set
screw on the switch and retest.
Disconnect the ohmmeter and reconnect the electrical leads to the inlet air pressure
switch.
Adjust the inlet gas pressure regulator to 5.5 ± 0.5 inches WC (see page 31).
Flo-Cal User Guide
Maintenance 33
Flame-Out Timer Settings
The flame-out timer is used to set the length of time that the Flo-Cal will automatically
attempt to relight the flame after a flame out. The time delay is set using switches on top of
the relay housing. Consult the following table for correct time delay settings.
Instrument Range
Time Delay
Relay Switch Settings
Standard BTU range
3.2 minutes
64 and 128
High BTU range
3.2 minutes
64 and 128
Low BTU range
6.4 minutes
128 and 256
Precision Gas Regulator Diaphragm Replacement
The precision gas regulator controls the sample gas pressure to the burner. If necessary, the
regulator diaphragm can be replaced as follows.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Shut down the Flo-Cal (see page 25).
Remove the two slotted screws and lift off the clear cover.
Remove the four hex head bolts to separate the Teflon discs and diaphragm from the
block.
Remove the small brass nuts and the tappet valve from the bottom of the discs.
Remove the four Allen head bolts to separate the two Teflon discs.
Remove the brass nut, lock washer, and aluminum disc.
Remove the diaphragm
Install a new diaphragm.
Reassemble the regulator in the reverse order while ensuring that the O-rings are in
place on the bottom of the lower disc. These O-rings must be oriented properly in
relation to the gas transfer ports on the block.
Air Control Valve Diaphragm Replacement
The air control valve controls the airflow to the burner. If necessary, the control valve
diaphragm can be replaced as follows.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Shut down the Flo-Cal (see page 25).
Remove the 1/4" Tygon tubing and nut from the cover.
Remove the four Allen head bolts and cover.
Remove the 5/16" brass hex nut, flat washer, and sealing washer from the shaft.
Remove the brass disc and the upper diaphragm.
Remove the second brass disk and spacer.
Remove the four slotted screws from the retaining ring. Remove the retaining ring.
Remove the small aluminum disc and lower diaphragm.
Reassemble the regulator in the reverse order. Do not allow the shaft to turn when
installing the 5/16" brass hex nut.
CAUTION: Do not allow the shaft to turn when installing the 5/16" brass hex
nut.
Flo-Cal User Guide
34
Maintenance
Measurement Range Change
The measurement range of the Flo-Cal calorimeter can be easily changed in the field by
replacing a single, plug-in resistor (R1) and selecting the appropriate transmitter range menu
setting. The following procedure should be followed to change the instrument range.
1.
Obtain a replacement 1% metal film resistor with the value shown in the following
chart for the desired measurement range.
Range Configuration Parameters
2.
Desired Range
R1 Value
Module Range Menu Setting
0.80 - 3.2 inches WC
90.9 ohms
40 - 100% (standard)
0.64 - 4.0 inches WC
124 ohms
33 - 100%
Locate the pressure transducer board. This board is located on the right inside surface
of the non-explosion proof model enclosure and in the bottom of the main enclosure
for the explosion-proof models. The following illustration shows the board layout.
Figure 4. Pressure transducer board with resistor location.
3.
4.
5.
6.
7.
Shut down the Flo-Cal (see page 25) and remove power from the system.
Unplug the existing resistor R1 from the pressure transducer board.
Plug the replacement resistor R1 into the socket on the pressure transducer board.
Apply power to the Flo-Cal system as outlined in the start up procedure (see page
23).
Set the transmitter module range menu settings to the appropriate values as shown in
the table above. See the Transmitter chapter (page 47) for instructions on setting
these parameters.
a. Set the Module Range to the appropriate zero and span percentages shown in the
table above.
b. Set the Alarms as appropriate for your configuration.
c. Set the Zero Value to the low inches WC from the range selected in the table
above.
Flo-Cal User Guide
Maintenance 35
8.
d. Set the Span Value to the high inches WC from the range selected in the table
above.
Calibrate the Flo-Cal as described in the Calibration chapter (page 41).
Constant Volume (CV) Pump
A positive displacement pump is used with Calorific Value instruments to provide a constant
volume of sample gas to the burner. The CV pump is not used on instruments designed to
measure Wobbe Index.
Description
The Constant Volume (CV) gas pump consists of an electric motor, a piston type pump head,
a spindle assembly, mounting base and a pump cylinder carrier. The pump cylinder carrier
also acts as a flow rate indicator. It is used to set the gas flow rate between 0 and 10 (10 being
the setting for maximum flow), on the scale located on the mounting base. The flow rate is
adjusted with the stroke length adjustment knob on the side of the pump base.
CAUTION: The stroke length adjustment of the CV pump must never be set to a
value below zero on the indicator.
Adjustment
Increasing the pump flow rate increases the calorific value measured by the calorimeter,
which increases the milliamp output signal. This increases the span of the calorimeter.
Decreasing the pump flow rate decreases the measured calorific value and the milliamp
output signal. This decreases the span of the calorimeter.
The pump flow rate may require adjustment during a full calibration of the Flo-Cal as
described beginning on page 43. To adjust the stroke length (and flow rate), loosen the two
knurled lock nuts, then turn the black knob on the pump head assembly (CW to decrease and
CCW to increase). Tighten the two knurled lock nuts when the stroke length setting is
completed.
Flo-Cal User Guide
36
Maintenance
Pump Maintenance
The pump should be lubricated monthly using the following procedure. Refer to the
following diagrams while performing this procedure.
Figure 5. CV pump base.
Flo-Cal User Guide
Maintenance 37
Figure 6. CV pump head, exploded view.
CAUTION: Use a light grade of G.P. (General Purpose) grease that does not
contain any fillers for lubricating the bearings and surfaces of the CV pump.
1.
2.
Record the stroke length indicator setting.
Turn power off to the pump.
CAUTION: When disassembling, if the piston is withdrawn more that 2" from
the cylinder, remove the lip seals and install them one at a time (see page 38). Lip
Seals will be damaged if this is not done.
3.
4.
5.
6.
Remove the pump head module as follows.
a. Adjust the stroke length adjustment to position the indicator to the extreme right
of the scale.
b. Rotate the spindle assembly to place the piston drive pin at the 3 o’clock position
when facing the cylinder head.
c. Loosen the two knurled nuts.
d. Lift the cylinder assembly up and to the right to disengage the piston drive pin
from the radial bearing. If the piston is withdrawn more than 2" from the
cylinder, the cylinder must be disassembled and the lip seals installed one at a
time (see page 38) to prevent lip seal damage.
Remove old grease from the radial bearing using a small brush or cotton swab. (The
bearing can be flipped over while still in the unit to access the back side).
Apply a thin coating of a light, general purpose grease (without filler) to the bearing
surfaces.
Wipe the steel spindle to remove old grease and dirt.
Flo-Cal User Guide
38
Maintenance
7.
8.
9.
10.
11.
12.
13.
14.
Clean the area around the lip seal of the piston and gently withdraw the ceramic
piston no more than 1 ¼ inch. (The piston may look dirty or like a smeared pencil
mark, but that is normal since it is made of a hard, crystalline carbon.) If the piston is
withdrawn more than 2" from the cylinder, the cylinder must be disassembled and
the lip seals installed one at a time (see page 38) to prevent lip seal damage.
Coat the drive pin on the end of the piston with a thin coating of light grease.
Turn the spindle so the radial bearing is at the 3 o’clock position.
Carefully insert the piston drive pin into the hole in the radial bearing while
positioning the cylinder assembly back into its normal operating position. Do not
permit the piston to extend from the cylinder more than 2 inches.
Ensure that the cylinder carrier is properly engaged with the slotted portion of the
follower.
Set the stroke length indicator to the correct setting.
Tighten the two knurled lock nuts.
Start up the system (page 24) and perform a calibration verification (page 42).
Lip Seal Replacement
The piston seals are precisely cut and hot formed from sheets of a chemically inert
fluorocarbon, specifically formulated for resistance to wear, abrasion, heat, and chemical
attack. Each lip seal possesses an exceptional mechanical memory which allows it to maintain
a relatively constant wiping pressure on the piston, compensating for seal wear as it occurs.
Properly maintained in clean condition, the original seals provided with the CV pump may be
expected to last the life of the pump.
Reinstalling Lip Seals
If the pump piston is withdrawn more than 2 inches, the following procedure must be
performed to reassemble the pump. Failure to follow this procedure will result in damage to
the lip seals.
1.
2.
3.
4.
5.
6.
7.
8.
If necessary, remove the cylinder assembly as outlined in the pump maintenance
procedure (page 36).
Remove the gland nut from the pump cylinder.
Carefully clean all contaminants from the gland washer, the two lip seals, and the
piston.
Position the gland nut and gland washer on the piston up against the drive pin.
Carefully place one of the lip seals on the piston with the lip side first. Rotate the seal
while inserting it on the piston until it is past the flat and on the piston neck.
Carefully place the second lip seal on the piston with the lip side last. Rotate the seal
while inserting it on the piston until it is past the flat and on the piston neck.
Insert the piston into the cylinder about one inch.
Screw the gland nut onto the cylinder threads and tighten.
Flo-Cal User Guide
Maintenance 39
Installing New Lip Seals
If the lip seals are to be replaced with new units, the following procedure must be performed.
1.
2.
3.
4.
5.
6.
7.
8.
8.
9.
10.
If necessary, remove the cylinder assembly as outlined in the pump maintenance
procedure (page 36).
Remove the gland nut from the pump cylinder.
Carefully clean all contaminants from the gland washer, the two lip seals, and the
piston.
Position the gland nut and gland washer on the piston up against the drive pin.
Form a lip around the piston on one of the lip seals by gently placing the lip seal on
the piston lip side last. Carefully rotate the seal on the piston while passing it over the
flat to the piston neck.
Remove the “formed” seal from the piston.
Carefully install the “formed” seal back on the piston, lip side first, while carefully
rotating the seal on the piston until it is past the flat and on the neck of the piston.
Gently place the second lip seal on the piston, lip side last, while carefully rotating
the seal on the piston until it is past the flat and on the neck of the piston.
Insert the piston into the cylinder about one inch.
Screw the gland nut onto the cylinder threads and tighten.
Set the seals as outlined in the next procedure.
Piston Seal Setting
After installing new lip seals, it is recommended that the seals be set (i.e., formed in place) by
fluid pressures generated by pump action using the following procedure.
1.
2.
3.
4.
5.
6.
7.
Block or close off the suction side (left) of the pump.
Set the stroke to the maximum setting.
Operate the pump spindle clockwise 10 to 20 turns (strokes) to create a vacuum in the
pump head. This will cause atmospheric pressure to shape the outer seal member
tightly around the piston.
Open the suction side of the pump.
Set the stroke indicator to the minimum setting to reverse the pumping direction.
Operate the pump while intermittently blocking the pump output (left port). This will
generate pressure in the seal area of the pump head causing the inner seals to form
around the piston.
Set the stroke length indicator to the normal operating position and reconnect all
tubing.
Flo-Cal User Guide
40
Maintenance
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Flo-Cal User Guide
Calibration 41
Chapter 7
Calibration
Calibration Gases
Calibration verification requires one calibration gas. This calibration gas should have a
Wobbe Index or Calorific Value (as appropriate) close to the typical value of the measured
gas.
Full calibration requires two calibration gases. The high calibration gas should have a Wobbe
Index or Calorific Value (as appropriate) that is at about 80% of the instrument measurement
range. The low calibration gas should have a Wobbe Index or Calorific Value (as appropriate)
that is at about 20% of the instrument measurement range.
Output Signal Calculation
The 4-20 mA signal output of the pressure transmitter is a calculated value providing a linear
representation of the heat value of the measured gas based on the range and type of
measurement. The displayed pressures on the front of the pressure transmitter are the raw
pressure measurements in inches of water column (WC). The expected milliamp output signal
for a particular instrument and a known heat value sample can be calculated using the
following equation.
Milliamp (mA) Output Value = (((H - A)/(B - A)) x 16 mA) + 4mA
where,
A = the lower range of the Flo-Cal
B = the higher range of the Flo-Cal
H = the Calibration Gas Heat Value
For example, if the Flo-Cal unit has a range of 750 to 1500 BTU/SCF and the Calibration Gas
value is 973.4 BTU/SCF, then,
A = 750, B = 1500, B - A = 750, H = 973.4
The expected milliamp signal output value for the calibration gas would be
(((973.4 - 750)/750) x 16 mA) + 4 mA = 8.77 mA
Flo-Cal User Guide
42
Calibration
Manual Calibration Procedures
Calibration Verification
Calibration verification requires a single calibration standard with a heat value near that of
the sample gas. The following procedure should be performed for calibration verification.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Determine the expected milliamp output for the heat value of the calibration standard.
Refer to the Output Signal Calculation section above (page 41) for the calculation
procedure. (Note: This value corresponds to a pressure reading on the pressure
transmitter when set to measure heat value, position 3. Future calibration
verifications with the same calibration standard can use the pressure rather than the
milliamp reading if desired.)
Connect the calibration standard to the Flo-Cal and allow to stabilize for at least 30
minutes.
Connect a digital ammeter in series with the 4-20 mA output of the pressure
transmitter. (This is not required if the expected transmitter pressure reading is
accurately known for the calibration standard used.)
Compare the actual milliamp output against the expected milliamp output as
calculated in step 1. (Alternately, compare the pressure displayed on the transmitter
with the value recorded for this particular calibration standard.)
If the output (or pressure) is high, adjust the 13 mm hex bolt on the expansion unit (at
the top right of the analyzer, see page 30) counterclockwise to produce a milliamp
reading (or pressure) within ± 0.16 mA of the expected value (or ± 0.024" WC for
pressure with a 0.8 to 3.2" WC range instrument). Make small adjustments and allow
the unit to stabilize between changes.
If the output (or pressure) is low, adjust the 13 mm hex bolt on the expansion unit
clockwise to produce a milliamp reading (or pressure) within ± 0.16 mA of the
expected value (or ± 0.024" WC for pressure with a 0.8 to 3.2" WC range
instrument). Make small adjustments and allow the unit to stabilize between changes.
If the unit cannot be adjusted to the correct value, perform a full calibration (see
below).
Remove the digital ammeter from the 4-20 mA current loop output (if used).
Switch the Flo-Cal back to measure sample gas.
Flo-Cal User Guide
Calibration 43
Full Calibration
Full calibration sets the instrument span and zero points. It is typically required at initial
startup, after major maintenance, and once a year thereafter. At other times, calibration
verification and zero adjustment are all that is required. Full calibration requires two
calibration standards with heat values at 20% and 80% of the instrument measurement range.
The following procedure should be followed to perform a full calibration.
1.
2.
3.
4.
5.
6.
7.
8.
Determine the expected milliamp output for the heat value of each of the two
calibration standards. Refer to the Output Signal Calculation section above (page 41)
for the calculation procedure.
Ensure that the Flo-Cal is stable before proceeding. Non-explosion proof units
require at least 45 minutes after start-up for stabilizing. Explosion proof units require
at least 2 hours after start-up for stabilizing (8 or more hours are recommended).
Connect the high (80%) calibration standard to the Flo-Cal and allow to stabilize for
at least 30 minutes.
Connect a digital ammeter in series with the 4-20 mA current loop output of the FloCal transmitter.
Record the actual milliamp output for the high calibration gas.
Connect the low (20%) calibration standard to the Flo-Cal and allow to stabilize for
at least 30 minutes.
Record the actual milliamp output for the low calibration gas.
Calculate the expected difference between the milliamp measurements of the two
calibration standards using the following equation and the values calculated in step 1.
expected output(cal 80%) – expected output(cal 20%) = expected milliamp signal span
9.
Calculate the actual difference between the milliamp measurements of the two
calibration standards using the following equation.
actual output(cal 80%) – actual output(cal 20%) = actual milliamp signal span
10.
If the actual milliamp signal span is not within ± 1% of the expected milliamp signal
span, adjust the span as follows.
a. If the actual span is smaller than the expected span, the unit is under spanned and
should be corrected as follows.
1) On Wobbe Index units, increase the gas flow to the burner by adding weights
to the precision gas regulator.
2) On Calorific Value units with a CV pump, adjust the pump stroke length (see
page 35) to increase the gas flow by setting the stroke length indicator to a
larger number at the pump.
3) Recheck the actual milliamp signal span and compare it to the expected span.
If it is within 1%, then continue to step 11 below. If the span cannot be
adjusted to within 1% of the expected, the gas or air (or both) orifice must be
replaced. Contact Thermo Fisher for assistance.
b. If the actual span is larger than the expected span, the unit is over spanned and
should be corrected as follows.
1) On Wobbe Index units, decrease the gas flow to the burner by removing
weights to the precision gas regulator.
2) On Calorific Value units with a CV pump, adjust the pump stroke length (see
page 35) to decrease the gas flow by setting the stroke length indicator to a
smaller number at the pump.
Flo-Cal User Guide
44
Calibration
CAUTION: Never set the stroke length of the CV pump to a value below zero on
the pump indicator scale.
11.
12.
13.
14.
15.
16.
17.
3) Recheck the actual milliamp signal span and compare it to the expected span.
If it is within 1%, then continue to step 11 below. If the span cannot be
adjusted to within 1% of the expected, the gas or air (or both) orifice must be
replaced. Contact Thermo Fisher for assistance.
Connect the high (80%) calibration standard to the Flo-Cal and allow to stabilize for
at least 30 minutes.
If the output is high, adjust the 13 mm hex bolt on the expansion unit (at the top right
of the analyzer) counterclockwise to produce a milliamp reading within ± 0.16 mA of
the expected value. Make small adjustments and allow the unit to stabilize between
changes.
If the output is low, adjust the 13 mm hex bolt on the expansion unit (at the top right
of the analyzer) clockwise to produce a milliamp reading within ± 0.16 mA of the
expected value. Make small adjustments and allow the unit to stabilize between
changes.
Connect the low (20%) calibration standard to the Flo-Cal and allow to stabilize for
at least 30 minutes.
Ensure that the milliamp output signal is within ± 0.16 mA of the expected value. If
not, repeat the full calibration procedure from the beginning.
Remove the digital ammeter from the 4-20 mA current loop output.
Switch the Flo-Cal back to measure the sample gas.
Automatic Calibration
The Flo-Cal analyzer can be supplied with an Auto-Cal unit to perform automatic calibration
verification and adjustment. Consult the Auto-Cal User’s Guide provided with your Flo-Cal
if it includes that option.
Flo-Cal User Guide
Calibration 45
Specific Gravity Calibration
Flo-Cal analyzers with optional specific gravity measurement typically require specific
gravity calibration if the instrument range needs to be changed or if the transmitter is
replaced. The following procedure should be followed to perform a specific gravity
calibration. (See page 47 for information about NORM DISPLAY and SETUP MODE
screens.)
1.
2.
3.
Determine the expected milliamp output for the heat value of each of the two
calibration standards. Refer to the Output Signal Calculation section (page 41 for the
calculation procedure.
Make sure MODULE RANGE (5th SETUP MODE screen.) is set at 30% - 100%.
If possible, measure the pressure difference in inches of water column (W.C.)
between the high and low specific gravity calibration gases. If you cannot measure
the pressure difference, use 1” W.C. for the zero value and 2” W.C. for the span
value as a starting point.
NOTE: These numbers are used as starting points for the zero and span values.
For example, if the low specific gravity gas reads 0.6” W.C. and the high reads
1.1” W. C., then set the zero value (10th SETUP MODE screen) at about 0.5”
W.C. and set the span value (11th SETUP MODE screen) at about 1.2-1.3” W.C.
4.
5.
6.
Connect the low (20%) calibration standard to the Flo-Cal and allow it to stabilize for
at least 15 minutes. Make sure the temperature has stabilized at 102° F, then continue
to the next step.
Select EDIT and FUNCTION to return to NORM DISPLAY, and check the low
specific gravity gas reading on the display or milliamp output,
Enter CAL MODE (1st SETUP MODE screen) and use ZERO CAL MODE and
adjust the setting to the calculated value for the low specific gravity gas calibration
standard.
NOTE: If you can not raise or lower ZERO VALUE, increase SPAN VALUE in
CAL MODE.
7.
8.
9.
10.
11.
Connect the high (80%) calibration standard to the Flo-Cal and allow it to stabilize
for at least 15 minutes. Make sure the temperature has stabilized at 102° F, then
continue to the next step.
Select EDIT and FUNCTION to return to NORM DISPLAY, and check the high
specific gravity gas reading on the display or milliamp output.
Reduce SPAN VALUE in MODULE RANGE (5th SETUP MODE screen) as
necessary to allow changes to ZERO VALUE.
Repeat steps 4 through 9, until both the high and low readings do not require further
adjustment. When the span value drops below 70%, make adjustments to MODULE
RANGE 1% or 2% at a time.
When the high and low specific gravity gases read close, change ZERO VALUE and
SPAN VALUE (10th and 11th SETUP MODE screens) one at a time in small steps
(example: .500” W.C. to .550” W.C.) to decide which value to raise or lower to get
best results. (Both can be changed if necessary.)
Flo-Cal User Guide
46
Calibration
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Flo-Cal User Guide
Transmitter 47
Chapter 8
Transmitter
Description
The pressure transmitter used with the Flo-Cal provides simultaneous display and alarm
functions. A 4-20mA analog output is provided for transmitting to other remote devices. The
transmitter is also equipped with a jumper selectable RS232 and RS485 Modbus bidirectional serial interface. Utilizing this serial port permits up to 128 Flo-Cal transmitters to
be connected to a single RS485 multidrop data highway.
System parameters are entered using a magnetic, non-intrusive keypad or a serial port. Menu
driven prompts allow easy setup of the many options including alarm set points and reset
options. Alarms may be high or low and latching or non-latching. A CAL MODE permits
setting of ZERO and SPAN from the keypad. Measurement ranges and engineering units are
also programmable from the keypad. An AUTHORIZATION MODE locks access to critical
parameters by requiring an access code.
The transmitter displays the inches of water column (WC) measured at various points in the
Flo-Cal. When operating in normal mode, the transmitter converts the pressure measurement
to a 4-20 mA current output that represents the range of the instrument measurement values.
Square root extraction is performed by the transmitter when calculating the appropriate
current loop output.
Operation
System Configuration Procedures
The transmitter is very simple to operate and user friendly. In minutes, an operator can
configure all variables to the desired settings. Following is a description of how to change
each transmitter variable.
Entering Variables Using the Magnetic Keypad
More detail about specific menu items follows in this section. The discussion here is intended
as generic instructions for utilizing the magnetic keypad for changing variables within each
menu. The following figure should be consulted while reading the instructions in this section.
Flo-Cal User Guide
48
Transmitter
Figure 7. Flo-Cal transmitter front panel with NORM display.
There are two modes of operation into which the transmitter display may be placed. These are
the NORM DISPLAY mode (see figure above) and the SETUP MODE. NORM DISPLAY is
the usual mode in which the 4 digit VALUE and 6 digits of ENGINEERING UNITS are
shown on the top line and the 16 digit MEASUREMENT NAME is shown on the bottom
line.
Flo-Cal User Guide
Transmitter 49
NORM DISPLAY may be exited and SETUP MODE entered at any time by passing the
magnetic wand over the FUNCTION key.
Figure 8. Setup Mode display.
On the display, “F” represents the FUNCTION key and “E” the EDIT key on all transmitter
setup screens. Passing the magnetic wand over FUNCTION again returns to NORM
DISPLAY mode. Passing the magnetic wand over EDIT enters the SETUP MODE at the top
of the list of configurable menu variables shown in the flow chart below.
To escape from any menu and return to NORM DISPLAY, depress the function key, or, after
approximately 2 minutes without a keystroke the transmitter will return to norm display
automatically.
Flo-Cal User Guide
50
Transmitter
+100.0 EUNITS
Measurement Name
Func
YES
Func
F = NORM DISPLAY
E = EDIT MODE
EDIT
YES
ENTER CAL MODE?
NO
0.000
EUNITS
ZERO MODE ACTIVE
EDIT
EDIT
XXXX UNLOCKED
NAME NO NAME
EDIT ACTIVATES
ZERO CAL MODE
FUNCTION
ALARM RELAY NO
ACKNOLEDGE
EDIT ACTIVATES
SPAN CAL MODE
FUNCTION
EDIT
EUNITS
Measurement Name
EDIT
100.0
EUNITS
SPAN MODE ACTIVE
+20.00 +100.0
MOD ZERO SPAN
YES
10.00%
INPUT
10.00%
OUTPUT
+20.00 LATCH Y H
EUNITS ALARM 1
20.00%
INPUT
20.00%
OUTPUT
+60.00 LATCH N H
EUNITS ALARM 2
30.00%
INPUT
30.00%
OUTPUT
+5.000 LATCH N F
EUNITS FAULT
40.00%
INPUT
40.00%
OUTPUT
+0.000 EUNITS
ZERO VALUE
50.00%
INPUT
50.00%
OUTPUT
+100.0 EUNITS
SPAN VALUE
60.00%
INPUT
60.00%
OUTPUT
EDIT KEY FOR
UNITY GAIN SETUP
70.00%
INPUT
70.00%
OUTPUT
1
9600 NONE
RTU BAUD PARITY
80.00%
INPUT
80.00%
OUTPUT
000s 32767
HI
TIMER MB MAX POS
90.00%
INPUT
90.00%
OUTPUT
DISPLAY LINEAR
TABLE
Y/N
NO
UP / DN FOR UNITY
EDIT TO EXIT
GAIN = UNITY
EDIT
EDIT
Note: When not in an edit mode, the FUNCTION key will return the display to the NORM
DISPLAY mode.
Figure 9. Menu flow chart.
Flo-Cal User Guide
Transmitter 51
After entering the SETUP MODE, configuration of all transmitter variables is accomplished
by selecting the appropriate SETUP MODE screen by passing the magnetic wand over the
or keys until it is displayed. Variables with few possible entries, such as YES/NO, may be
changed by passing the magnetic wand over EDIT, which causes a flashing cursor to appear
over the variable. Passing the magnetic wand over the or keys will step through the
available entries. Variables requiring many different characters to be entered are also changed
by passing the magnetic wand over EDIT. EDIT begins the flashing cursor, but then passing
the magnetic wand over FUNCTION causes the cursor to move from one character within
the variable to the next. Continue to pass the magnetic wand over FUNCTION until the
cursor is under the character to be changed and use the or keys to change it. Number only
variables, such as alarm levels, may be set quickly since the only possible entries for each
character are the 10 decimal numbers and a decimal point. Other more descriptive entries
have many more characters that are possible. With the cursor under the character to be
changed, pass the magnetic wand over the or key to step through the available character
string in the order listed below
ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz !”#$%& `( )*+,./0123456789:;<=>?@
Passing the magnetic wand over the key steps through the above character string from left to
right and the key from right to left. Continue this until the desired character appears, then
pass the magnetic wand over FUNCTION to move the cursor to the next position within a
field. When each character of the variable appears as desired, pass the magnetic wand over
EDIT to enter it. The cursor will jump to the next variable on this screen (if there is another)
and begin flashing over it. Move to the next SETUP MODE screen by passing the magnetic
wand over or when the flashing cursor is not present.
Please remember that variable configuration is a one time task that takes only a few minutes
to complete. It does not require repeating after power off conditions since all variables are
stored in non-volatile RAM.
Flo-Cal User Guide
52
Transmitter
Setup Screen Descriptions
Cal Mode
The 1st SETUP MODE screen provides a path into the transmitter CAL MODE, shown
below. This feature allows readings to be corrected electronically at the transmitter keypad
even when the error may exist at the remote sensor or transmitter. To begin the CAL MODE,
toggle the YES / NO option to YES and pass the magnetic wand over EDIT. Another screen
appears which instructs the operator to pass the magnetic wand over EDIT in order to
activate the ZERO CAL mode. This will bring the current engineering unit reading to the
transmitter display. The input should have a ZERO stimulus applied so that a known ZERO
value is present at the transmitter input. The or keys may be used to apply a positive or
negative offset to cause the engineering unit value to match the ZERO stimulus. When the
ZERO is complete, passing the magnetic wand over EDIT and then the key brings the
display to the entrance of the SPAN CAL mode. Passing the magnetic wand over EDIT again
enters the SPAN CAL mode. The display again reflects the correct engineering unit values
for the input signal presently being applied. A SPAN stimulus should be applied to the input
so that a known SPAN engineering unit value is present. The or keys may be used to increase
or decrease the transmitter gain settings until the engineering unit value matches the SPAN
stimulus. Passing the magnetic wand over EDIT again returns to the SETUP MODE.
RETURN
TO MAIN
DISPLAY
0.000 _
EUNITS
ZERO MODE ACTIVE
YES
YES
ENTER CAL MODE?
EDIT
EDIT
EDIT ACTIVATES
ZERO CAL MODE
FUNCTION
EDIT ACTIVATES
SPAN CAL MODE
FUNCTION
EDIT
EDIT
100.0 _
EUNITS
SPAN MODE ACTIVE
Figure 10. Cal mode flow chart.
Flo-Cal User Guide
Transmitter 53
Supervisor System Lock
A method for preventing unauthorized personnel from tampering with the configuration of
any of the transmitter variables has been provided in the first SETUP MODE screen. If an
attempt is made to change any variable after the system is locked, a MODE IS LOCKED
message will appear and none of the variables may be altered. To check the status of this
feature, enter the SETUP MODE and view the AUTHORIZATION SCREEN shown below.
Figure 11. Authorization screen.
The CODE field, displayed as XXXX, is where the 4 digit authorization code is entered. If
the status is UNLOCKED, a code may be entered as described in section 3.2. After entering
the code once, a prompt will appear asking it to be repeated. If it is not entered correctly the
second time, a CODE MISMATCH message will appear. After it is entered properly the
second time, the cursor will flash over the U in the UNLOCKED field. Passing the magnetic
wand over or will lock the SETUP MODE. NAME is a 10 character field where a
supervisory contact should be entered who knows the authorization code.
Always enter the name of an individual with the authorization code in this field. The
procedure for resetting a transmitter with a lost authorization code requires all configuration
data to be erased and reentered. This reset procedure is not described in this manual for
security reasons. Contact Thermo Fisher if this becomes necessary.
To change the MENU status back to UNLOCKED, enter the 4 digit code again and pass the
magnetic wand over ENTER.
Alarm Relay Acknowledge Feature
It is sometimes desirable to have a method by which alarm trips may be “acknowledged”
while the problem causing the alarm is serviced. This is often the case when an annoying
horn or strobe light is driven from the alarm's relay output. The second SETUP MODE screen
allows enabling of the RELAY ACKNOWLEDGE feature, which only applies to the
ALARM 2 relay. It is shown below.
Figure 12. Alarm 2 relay acknowledge feature screen.
The RELAY ACKNOWLEDGE screen has a YES/NO option field. If the field is set to NO,
the relay for each alarm is always activated when that alarm is on. If the field is set to YES,
the ALARM 2 relay activates initially when the alarm is on, but may then be de-activated by
the ALARM RESET function. Applying an ALARM RESET function does not affect the
ALARM 2 LED. If the ALARM 2 condition goes away and then returns, the ALARM
RESET function must be applied again to deactivate the relay.
Flo-Cal User Guide
54
Transmitter
ALARM RESET may be applied in 3 different ways; by passing the magnetic wand over the
ALARM RESET key on the keypad, by applying a contact closure to the remote ALARM
RESET input terminals on TB1, or by applying an ALARM RESET code to the Modbus®
serial interface.
Measurement Description and Engineering Units
The 4th SETUP MODE screen is where the 6 digit engineering unit and the 16 digit
MEASUREMENT DESCRIPTION labels are entered. It is shown below.
Figure 13. Measurement description.
Engineering Units
This 6 character field is where the units of measure for the input are entered. For example, if
an input module is installed for 100 ohm platinum RTD that is calibrated for 0-100 degrees
centigrade, then Deg C might be entered here. Deg F could also be entered if it is desired to
display the data this way. When this field is entered, it will appear throughout the remainder
of the menus in places where the entry needs to be in engineering units of measure.
Measurement Description
This is a 16 character field that the user can utilize as an ID tag to describe the monitored
variable using familiar terminology. This ID tag will appear on the lower line of the NORM
DISPLAY screen. It is especially useful when several transmitters are monitoring variables
from different locations since it may be used to identify each location. It may also be read
from the serial port.
Module Range
This very important entry allows flexible use of an input module's range. It is the 5th SETUP
MODE screen and is shown below.
Figure 14. Module zero and span.
The percentage of the input's range to be utilized may be entered on this screen. Any value
between 0-100% may be entered, but it is recommended that no less than a 20% of full scale
range be used in order to avoid noise problems caused by over amplifying the input signal.
This means the difference between the ZERO % value and the SPAN % value should be no
less than 20%.
Flo-Cal User Guide
Transmitter 55
For example, if a 7B module for an RTD input had a calibrated range of 0-100 degrees C, and
if we want to measure 0-100 degrees C, we must enter 0-100% into the MOD ZERO &
SPAN menu entries. However, if we are only interested in 20-40 degrees C, we may enter
only 20-40% into these menu entries and the transmitter display will focus on this narrower
range. The same 7B module may be used in both examples. that 20° C (or 68° F) must be
entered in the ZERO VALUE and 40° C (or 104° F) must be entered for the SPAN VALUE
when configuring the measurement range in the 9th and 10th SETUP MODE screens as
described in sections 4.9 & 4.10 of this manual.
Activating Linearization
The 6th SETUP MODE screen is provided to allow non-linear inputs to be linearized by the
manual keypad entry of a 10 breakpoint linearization curve. This screen is shown below.
Figure 15. Display linear table screen.
This screen asks DISPLAY LINEAR TABLE, which is followed by a YES / NO option.
Entering NO does not mean that linearization is not being applied. It is possible to have a
curve entered and not display it when scrolling through the SETUP MODE. Entering YES
and displaying the curve means that 9 additional screens must be scrolled through when
traversing the SETUP MODE. If the curve does not require frequent modification, it is
recommended that it be displayed only during the initial setup. The 9 screens that make up
the LINEAR TABLE are shown below.
Flo-Cal User Guide
56
Transmitter
+20.00 +100.0
MOD ZERO SPAN
10.00%
INPUT
10.00%
OUTPUT
20.00%
INPUT
20.00%
OUTPUT
30.00%
INPUT
30.00%
OUTPUT
40.00%
INPUT
40.00%
OUTPUT
50.00%
INPUT
50.00%
OUTPUT
60.00%
INPUT
60.00%
OUTPUT
70.00% N
INPUT
70.00%
OUTPUT
80.00%
INPUT
80.00%
OUTPUT
90.00%
INPUT
90.00%
OUTPUT
YES
DISPLAY LINEAR
TABLE
Y/N
NO
+20.00
EUNITS
LATCH Y H
ALARM 1
Figure 16. Linear table flow chart.
The OUTPUT values, in percent of full scale, are constants that may not be modified. The
INPUT values, also in percent of full scale, must be entered by the user. Transmitter users
wishing to utilize the linearization feature are responsible for correctly entering breakpoint
values. Typically, the nine breakpoint values are available to the user on a graph or table
depicting the curve to be linearized. For example, if the input signal was at 70% of full scale
when the correct engineering unit values were only 50% of full scale, 70% should be entered
as the INPUT for the 50% OUTPUT. The INPUT and OUTPUT signals are expected to
match at 0% and 100%. Therefore, there is no menu entry for entering these points.
Alarm 1 Setup
The 7th SETUP MODE screen, shown below, determines for alarm 1, the trip point level, if it
is latching or nonlatching, and if it trips on high or low going signals.
Figure 17. Alarm 1 parameters.
Flo-Cal User Guide
Transmitter 57
The trip point must be entered within the active range of engineering units being monitored.
If it is desired that ALARM 1 reset automatically when the alarm condition clears, enter N
after LATCH. If it is desired that an ALARM RESET function must be applied before
allowing ALARM 1 to reset, enter L after LATCH.
The last character position on the top line may be toggled to either an H for high level trips,
or an L for low level trips. H causes the alarm to trip as the reading exceeds the trip point and
L as the reading falls below the trip point. There is 1 percent deadband to prevent the alarms
from chattering when the reading is equal to the trip point.
Alarm 2 Setup
The 8th SETUP MODE screen, shown below, determines the ALARM 2 trip point level and
if it is latching or nonlatching and high or low. It is identical to ALARM 1 in respect to
deadband.
Figure 18. Alarm 2 parameters.
Fault / Alarm 3 Setup
The 9th SETUP MODE screen, shown in the figure below, determines if the FAULT /
ALARM 3 alarm functions as a third level alarm or as an underrange indicating FAULT
alarm.
Figure 19. Fault or Alarm 3 parameters.
To configure it for a level alarm requires that the last character on the top line be set to an A
as shown in the figure above. The trip point and latching / nonlatching options are then
configured the same as for ALARM 2.
To configure as a FAULT alarm requires that the last character on the top line be set to an F
as shown in the figure above. The trip point entered will represent how far below the defined
measurement range may the signal stray before the FAULT alarm is tripped. In the earlier
example of 0-100 DEG C for the signal range; if 3.000 were entered for the FAULT
THRESHOLD, then a FAULT alarm would occur when the signal fell below -3.000 DEG C.
Flo-Cal User Guide
58
Transmitter
Zero Value
The 10th SETUP MODE screen, shown below, determines the low end of the measurement
range. In the above example, using 100% of the 0-100 degrees C 7B module (it is possible to
use smaller portions of 7B module spans, as discussed in section 4.4), the ZERO VALUE
would be 0.000 deg C or 32.00 deg F.
Figure 20. Zero value.
Span Value
The 11th SETUP MODE screen, shown below, determines the upper end of the measurement
range. In the example above, 100.0 deg C or 212.0 deg F would be entered here if 100% of
the 7B module span were to be used. It is important to understand that the ZERO VALUE
and the SPAN VALUE entries must define 0-100% of full scale in engineering units for the
display.
Figure 21. Span value.
Unity Gain Setup
The 12th SETUP MODE screen, shown below, provides a means of instantly placing the
CAL MODE (described in section 4.12) into UNITY GAIN. UNITY GAIN means there are
no offset or gain factors being applied to the input. It is being displayed same as it is received.
To apply UNITY GAIN, bring the screen on the right below up and pass the magnetic wand
over EDIT and then either or . The transmitter will briefly show the GAIN = UNITY
screen.
UP / DN FOR UNITY
EDIT TO EXIT
EDIT EDIT KEY FOR
EDIT UNITY GAIN SETUP
GAIN = UNITY
Figure 22. Unity Gain function.
Flo-Cal User Guide
Transmitter 59
Serial Port Setup
The 13th and 14th SETUP MODE screens are for configuring the Modbus serial port. The
13th is for RTU address number, baud rate and parity. The 14th is for entering the Modbus
maximum which may be either 9999 or 32767, and the ASCII position of the data which may
be either high byte or low byte. The 000s TIMER field allows activation of a hardware switch
that may be used to enable two external serial ports. The transmitter will wait for this delay
period, upon loss of serial port activity, before switching to another external port in an
attempt to re-establish communications. These variables must be set to conform to
requirements of the specific host computer system that receives the transmitter serial data.
1
9600 NONE
RTU BAUD PARITY
000s
32767
HI
TIMER MB MAX POS
Figure 23. Modbus serial port configuration.
System Hardware
The transmitter consists of four round circuit board assemblies. The CPU, MEMORY and
DISPLAY boards mate together piggy back in a stack assembly with 44 pin board to board
connectors. The CPU board is on the bottom of the stack, farthest from the front panel, and
has a 12 pin heavy duty male connector mounted on its solder side. This connector mates
with a similar female connector on the I/O board. Removal of the stack with power applied
conditions will not damage the unit.
WARNING: Do not open the transmitter housing with power applied unless
the area is known to be non-hazardous. Do not attempt to connect or
disconnect components with power applied unless the area is known to be nonhazardous.
CPU Board
The transmitter CPU is an Intel 80C196KB 16 bit microcontroller with a clock frequency of
12MHZ.
The CPU board, farthest from the front panel in the 3 board stack, contains the 16 bit microcontroller (U2), preamplifier (U4), D/A Converter (U7), 4-20mA output circuit (U10), along
with circuitry for the 5 volt reference and watchdog timer. The preamplifier includes ZERO
(R4) and SPAN (R8) adjustments. In addition, the D/A Converter includes a SPAN (R10)
adjustment that is used to set the full scale value of the analog output signal. The calibration
procedure for these adjustments follows.
Flo-Cal User Guide
60
Transmitter
Calibration
Note: The 3 potentiometers located on the CPU board are set at the factory and normally need
no further adjustment. The following procedure is provided in the event that a major
component is replaced or the adjustments are inadvertently tampered with.
1.
2.
3.
4.
Since the transmitter is equipped with an electronic CAL MODE, it is important that
prior to calibrating the potentiometers, the electronic CAL MODE be placed into
UNITY GAIN. Otherwise, it is possible that readings may have offset and gain
applied electronically. Place the transmitter into UNITY GAIN by following the
procedure on page 58.
Return to the NORM DISPLAY screen for viewing the input value in engineering
units. Apply a stable 0% full scale analog signal to the analog input terminals. Adjust
the ZERO potentiometer R4 until the transmitter displays the correct ZERO reading.
Apply a stable 100% full scale signal to the analog input terminals. Adjust the SPAN
potentiometer R8 until the transmitter displays the correct SPAN value.
Note: The next step may be skipped if the analog output is not utilized.
Measure the analog output using a digital multimeter. The standard analog output
from the transmitter is 4-20mA. Therefore, with the 100% full scale input applied,
adjust the analog SPAN potentiometer (R10) for 20mA at the analog output
terminals.
Memory Board
The MEMORY board, middle in the 3 board stack, contains the socketed EPROM firmware
(U3 & U4) and PAL (U6), the NON-VOLATILE RAM (U5), and the RAM IC's (U7 & U8).
It is the middle of the three “stack” boards connected by the 44 pin connector.
Display Board
The Display board, top of the 3 board stack, contains the 16-character, 2-line alphanumeric
LCD display and supporting circuitry including the contrast adjustment potentiometer (R1).
Indicating LED's showing the condition of discrete variables such as alarms, serial port
transmit and receive lines, keypad, and CPU operation are on the DISPLAY board. The
magnetic keypad switches allowing non-intrusive control of the transmitter are on this board.
Input/Output Board
The Input/Output board (I/O) has the optional plug in Input signal conditioning module and
the alarm relays mounted on the solder side. No signal conditioning module is required for
non-isolated 4-20 mA or 1-5VDC inputs. The component side has the RS232 port (U4),
RS485 port (U2 & U3), and the jumpers for configuring the serial port to be either RS232 or
RS485. In addition, the 5 volt switching power supply and TB1 & TB2 are on the I/O board.
RS-232 / RS-485 Configuration
The transmitter is equipped with RS232 and RS485 serial interface circuits. Either may be
selected by placement of jumpers on the I/O PCB.
Flo-Cal User Guide
Transmitter 61
Terminal Block Connections
Terminal block connection assignments are shown in the following tables.
TB1 Connections
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Power Plus
Alarm 1 NO
Power Minus (COMMON with SB1 installed)
Alarm 1 Common
Analog Output Plus
Alarm 1 NC
Analog Output Minus
Alarm 2 NO
Remote Alarm Reset
Alarm 2 Common
RS-485 RXB / RS-232 COMMON
Alarm 2 NC
RS-485 RXA
*Fault / Alarm 3 NO
RS-485 TXB / RS-232 RXD
*Fault / Alarm 3 Common
RS-485 TXA / RS-232 TXD
*Fault / Alarm 3 NC
*Fail Safe; NO opens on alarm
TB2 Connections
1
2
3
Excitation Plus (24VDC with JP7 installed)
Analog Input Plus
Analog Input Minus (circuit COMMON with
JP6 installed)
Flo-Cal User Guide
62
Transmitter
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Flo-Cal User Guide
Getting Help 63
Chapter 9
Getting Help
Additional Information
NOTE: In the interest of completeness, manuals and drawings included with the
system may provide information pertaining to options not included with your
system. Information in application notes supersedes general information in these
documents.
Additional information can be obtained from the following sources.
Flo-Cal User Guide
Auto-Cal II User’s Guide
System drawings
Application notes for the supplied system
Manuals and data sheets for other equipment
The application notes supplied with each system include information specific to the
configuration of the installed system. These notes will typically include pressure settings,
flow settings, temperature settings and other special situations or adjustments.
Getting Help
Answers to many questions concerning the analyzer system can be found in this manual and
other documentation provided with the system. If a problem or question is encountered that is
not covered in the documentation, assistance is available Monday through Friday (except
holidays), from 8 a.m. to 5 p.m. Central time. To obtain assistance, please call Thermo Fisher
at (713) 272-0404, or fax us at (713) 272-2272.
For assistance during times other than normal business hours, consult our web site at
http://www.thermofisher.com. This site includes equipment information, news releases, and
other information. Alternately, you can call (713) 272-0404 and leave a voice message or you
can send a fax to (713) 272-2272.
Flo-Cal User Guide
64
Getting Help
To contact Thermo Fisher:
Address:
Thermo Fisher Scientific
Process Instruments Division
1410 Gillingham Lane
Sugar Land, TX 77478
USA
Phone: 713-272-0404
Fax: 713-272-2272
Web: www.thermofisher.com
Flo-Cal User Guide
Glossary 65
Chapter 10
Glossary
Auto-Cal
An automatic calibration option available with the Flo-Cal calorimeter.
BTU/SCF
British Thermal Unit per Standard Cubic Foot measured at 60° F and 30" Hg.
Calorific Value (CV)
The heat value of a gas at standard conditions expressed as Gross Heating Value (HHV) or
Net Heating Value (LHV).
CCW
Counter-clockwise
CPU
central processing unit (computer)
CV
Calorific Value or Constant Volume (pump).
CW
clockwise
Density
Density denotes the ratio of the mass of a substance to its volume, expressed in grams per
cubic centimeter or pounds per cubic foot.
Fault
An error condition.
Flo-Cal User Guide
66
Glossary
Flame-Out
Indicates that the burner flame is extinguished.
Field
A category of information in a table. Fields contain such information as component names,
elution times, Alarm numbers, etc.
Gross Heating Value
The theoretical heat value of a gas at standard conditions.
Heat Value
A term used interchangeably for Calorific Value or Wobbe Index. It expresses the heat
energy per unit volume of a fuel gas. It can be expressed as BTU/SCF, MJ/Nm3, or
Kcal/Nm3.
HHV
Gross Heating Value.
Kcal/Nm3
Kilocalories per normal cubic meter measured at 0° C and 760 mm Hg.
LED
Light Emitting Diode. Often used as an alarm or status indicator for electronic equipment.
Colors available include red, green, yellow, and orange.
LHV
Net Heating Value.
MJ/Nm3
Megajoules per normal cubic meter measured at 0° C and 760 mm Hg.
Net Heating Value
The actual available heat value of a gas at standard conditions. This is frequently used to
determine the heat potential of a fuel gas.
PCB
Printed circuit board containing the electronic components performing one or more functions.
Flo-Cal User Guide
Glossary 67
Specific Gravity
Specific gravity, a term being replaced by relative density, is the ratio of the density of a
given substance to the density of a standard of reference at standard temperature and pressure.
The standard of reference for solids and liquids is the density of water. For gases, it is the
density of air.
STP
Standard temperature and pressure conditions (0° C and 760 mm Hg).
WC
Water column, a measurement of gas pressure expressed in inches of water.
Wobbe Index
A measure of the combined effects of fuel gas, heat value, and specific gravity changes to
provide a meaningful measure of a gas’s actual heating characteristics.
Flo-Cal User Guide
68
Glossary
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Flo-Cal User Guide
Appendix A 69
Appendix A
Flame-Out & Overrange
Flame-Out System
The flame-out system automatically shuts off the gas source, CV pump (Calorific Value units
only), and sparking ignitor if the burner flame fails to light within the preset time limit (3.2 or
6.4 minutes depending on BTU range of instrument). Refer to the Flame-Out Control Matrix
table (below) and the electronic schematic at the end of this appendix.
If electrical power, gas flow, or air flow to the Flo-Cal analyzer is lost, the burner flame will
extinguish. When the lost power or flow is restored, the flame-out time-delay relay is
energized to allow the burner flame to re-light. If the flame does not re-light within the delay
time, a solenoid valve in the gas supply line is de-energized and the flame-out alarm contact
is closed. The CV pump (where used) and sparking unit are also de-energized. The system
functions in a similar manner when power is first applied to the analyzer.
To re-light the flame after the time-delay relay trips, the reset button must be momentarily
depressed and released or the electrical power to the analyzer must be cycled. If the flame
still fails to light, consult the maintenance chapter (page 27).
Flame-Out Control Matrix
Input
CONDITION
Control
air
inlet gas flame out over range flame out
sw
relay
press sw press sw press sw
Output
over range
inlet gas
relay
solenoid
sparking
CV pump
unit
initial
power on
closed?
closed?
closed
open
off
delaying
off
open
on
on
normal,
flame on
closed?
closed?
open
open
off
off
open
off
on
initial
flame out
closed?
closed?
closed
open
off
delaying
off
open
on
on
3.2 or 6.4
minutes after
flame out
closed?
closed?
closed
open
on
off
closed
off
off
Reset pushed
w/flame out
?
system goes to initial flame-out states
These switches will be open if the air or inlet gas pressure is too low.
Flo-Cal User Guide
70
Appendix A
Overrange system
If an over-range condition develops, the Flo-Cal calorimeter automatically extinguishes the
burner flame. After five minutes, the flame is automatically allowed to re-ignite. Refer to the
Over-Range Control Matrix (below) and the electronic schematic at the end of this appendix.
If an over-range condition develops, the over range alarm output on the transmitter closes and
initiates the over range time-delay relay. The relay immediately closes the inlet gas solenoid
and turns off power to the sparking unit and the CV pump (where used). When the inlet gas
solenoid closes, burner gas is lost and the analyzer flame goes out. After a delay of five
minutes, the over range relay turns off. The inlet gas solenoid is then opened and power is
applied to the sparking unit and the CV pump. The flame-out circuit then attempts to re-light
the flame (see the description on the flame-out system on the preceding page).
Over-Range Control Matrix
INPUT
CONDITION
CONTROL
air
inlet gas flame out over range flame out
sw
relay
press sw press sw press sw
OUTPUT
over range
inlet gas
relay
solenoid
sparking
unit
CV
pump
initial
power on
closed?
closed?
closed
open
off
delaying
off
open
on
on
normal,
range ok
closed?
closed?
open
open
off
off
open
off
on
initial
over range
closed?
closed?
open
closed
off
on
delaying
closed
off
off
5 min after
over range
closed?
closed?
closed
open
off
delaying
off
open
on
on
flame-out
conditions
?
When the over range relay times out (after 5 minutes), the conditions become
identical to an initial flame out as shown in the Flame-Out Control Matrix (above).
These switches will be open if the air or inlet gas pressure is too low.
Flo-Cal User Guide
Appendix A 71
Figure 24. Electronic schematic of the Flo-Cal Flame-out and Over-range circuits.
Flo-Cal User Guide
72
Appendix A
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Flo-Cal User Guide
Appendix B 73
Appendix B
Pressure Conversion
Charts
Typically, the Flo-Cal pressure transmitter measures up to 3.2" WC. This range is not high
enough setting the inlet air or inlet gas pressures. Therefore, a Test Point Switch push-button
is available to momentarily extend the range of the pressure transmitter when setting the inlet
pressures. This momentary push-button is located on the pressure transducer board inside the
Flo-Cal (see page 34). When the Test Point Switch is depressed, the range is changed to 0 –
8.3 inches WC. The range returns to the normal values when the push-button is released.
When in the extended range mode (i.e., the push-button depressed), the actual pressure
measurement must be calculated from the transmitter reading. The following equations can be
used to determine the pressure when the push-button is depressed.
To determine the actual measured pressure for a displayed value with the push button
depressed, use the following formula.
To determine the displayed pressure for a desired pressure with the push button depressed,
use the following formula…
The following pressure conversion tables can also be used to determine measured pressures.
To use, select the table that corresponds to the normal measurement range, and then find the
measured pressure that corresponds to the transmitter reading.
Flo-Cal User Guide
74
Appendix B
Table for 0.80 - 3.2" WC instruments
Actual
Pressure
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
3.60
3.70
3.80
3.90
4.00
4.10
4.20
4.30
4.40
Flo-Cal User Guide
Displayed
Pressure
0.000
0.039
0.077
0.116
0.154
0.193
0.231
0.270
0.308
0.347
0.386
0.424
0.463
0.501
0.540
0.578
0.617
0.655
0.694
0.733
0.771
0.810
0.848
0.887
0.925
0.964
1.002
1.041
1.080
1.118
1.157
1.195
1.234
1.272
1.311
1.349
1.388
1.427
1.465
1.504
1.542
1.581
1.619
1.658
1.696
4.50
4.60
4.70
4.80
4.90
5.00
5.10
5.20
5.30
5.40
5.50
5.60
5.70
5.80
5.90
6.00
6.10
6.20
6.30
6.40
6.50
6.60
6.70
6.80
6.90
7.00
7.10
7.20
7.30
7.40
7.50
7.60
7.70
7.80
7.90
8.00
8.10
8.20
8.30
1.735
1.773
1.812
1.851
1.889
1.928
1.966
2.005
2.043
2.082
2.120
2.159
2.198
2.236
2.275
2.313
2.352
2.390
2.429
2.467
2.506
2.545
2.583
2.622
2.660
2.699
2.737
2.776
2.814
2.853
2.892
2.930
2.969
3.007
3.046
3.084
3.123
3.161
3.200
Appendix B 75
Table for 0.64 - 4.0" WC instruments
Actual Pressure
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
3.60
3.70
3.80
3.90
4.00
4.10
4.20
4.30
4.40
Displayed
Pressure
0.000
0.048
0.096
0.145
0.193
0.241
0.289
0.337
0.386
0.434
0.482
0.530
0.578
0.627
0.675
0.723
0.771
0.819
0.867
0.916
0.964
1.012
1.060
1.108
1.157
1.205
1.253
1.301
1.349
1.398
1.446
1.494
1.542
1.590
1.639
1.687
1.735
1.783
1.831
1.880
1.928
1.976
2.024
2.072
2.120
4.50
4.60
4.70
4.80
4.90
5.00
5.10
5.20
5.30
5.40
5.50
5.60
5.70
5.80
5.90
6.00
6.10
6.20
6.30
6.40
6.50
6.60
6.70
6.80
6.90
7.00
7.10
7.20
7.30
7.40
7.50
7.60
7.70
7.80
7.90
8.00
8.10
8.20
8.30
2.169
2.217
2.265
2.313
2.361
2.410
2.458
2.506
2.554
2.602
2.651
2.699
2.747
2.795
2.843
2.892
2.940
2.988
3.036
3.084
3.133
3.181
3.229
3.277
3.325
3.373
3.422
3.470
3.518
3.566
3.614
3.663
3.711
3.759
3.807
3.855
3.904
3.952
4.000
Flo-Cal User Guide
76
Appendix B
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Flo-Cal User Guide
Appendix C 77
Appendix C
Modbus
Modbus communication is an option available with the Flo-Cal for connection to a
Distributed Control System (DCS). Consult the application notes included with the
instrument for information on Modbus address mapping when included.
Flo-Cal User Guide
78
Appendix C
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Flo-Cal User Guide
Appendix D 79
Appendix D
Toxic & Hazardous
Substances Tables*
*English and Chinese versions.
The Toxic & Hazardous Substances tables for Flo-Cal (ATEX and Safe Area) can be found
on the following pages.
Flo-Cal User Guide
80
Appendix D
Figure 25. Toxic & Hazardous Substances Tables – Flo-Cal (ATEX)
Flo-Cal User Guide
Appendix D 81
Figure 26. Toxic & Hazardous Substances Tables – Flo-Cal (Safe Area)
Flo-Cal User Guide
82
Appendix D
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Flo-Cal User Guide
Index 83
Index
Index
4
4-20 mA
Calculations – 41
A
Additional information – 63
Air control valve
Diaphragm – 33
Alarm
# 2 – 15
Relay acknowledge feature – 53
Setup #1 – 56
Setup #2 – 57
Setup #3 – 57
Setup Fault – 57
Analytical specs – 8
Annual maintenance – 27
Applications – 11
Auto-cal
Definition – 65
Option – 15
Transmitter – 52, 58
Verification – 42
Calorific value
Definition – 65
Calorific value
Explanation – 14
Mode – 12, 14
CCW – 65
Constant volume pump
Adjustment – 35
Description – 35
Lip seal replacement – 38
Maintenance – 36
CPU
Definition – 65
CV
Definition – 65
CW
Definition – 65
D
Daily maintenance – 27
Density
Definition – 65
B
BTU/SCF
Definition – 65
Burner
Primary air adjustment – 28
C
Calibration – 41
Automatic – 44
Full – 43
Gases – 41
Hazards – 5
Manual – 42
Output signal – 41
Safety – 5
Specific Gravity – 45
E
Electrical installation – 20
F
Fault
Definition – 65
Features chart – 7
Field
Definition – 66
Flame
Relight – 28
Flame-out
Definition – 66
Detection – 15
Switch – 31
Flo-Cal User Guide
84
Index
System details – 69
Timer settings – 33
Functional diagram – 13
G
Gas & air installation – 22
Getting help – 63
Glossary – 65
Gross heating value
Definition – 66
Gross heating value
Description – 12
H
Hardware specs – 8
Heat value
Definition – 66
Help – 63
HHV
Definition – 66
How to Use This Manual – 1
I
I/O specs – 9
Inlet air
Adjust – 30
Pressure switch – 15, 31
Inlet gas
Adjust – 31
Pressure switch – 15
switch – 32
Installation – 17
Electrical – 20
Gas & air – 22
Physical – 17
Instrument air – 22
Introduction – 11
K
Daily – 27
Monthly – 27
Procedures – 28
Schedule – 27
Weekly – 27
Yearly – 27
Manual shutdown – 25
Measurement range
Changing – 34
MJ/Nm3
Definition – 66
Modbus
Information – 77
Serial port setup – 59
Mode
Calorific value – 14
Types available – 12
Wobbe index – 12
Monthly maintenance – 27
N
Net heating value
Definition – 66
Net heating value
Description – 12
O
Operation
Calorific value – 14
Modes – 12
Theory – 12
Wobbe index – 12
Options list – 15
Output signal
4-20 mA calculations – 41
Overrange
Detection – 15
System details – 70
P
3
Kcal/Nm
Definition – 66
L
LED
Definition – 66
LHV
Definition – 66
M
Maintenance – 27
After service – 27
Flo-Cal User Guide
PCB
Definition – 66
Precision gas regulator
Diaphragm – 33
Pressure
Conversion charts – 73
Inlet air adjust – 30
Inlet gas adjust – 31
Measurement – 29
Pressure switch
Flame-out – 31
Inlet Air – 31
Inlet gas – 32
Primary air
Index 85
adjustment – 28
Pump
Constant volume – 35
Constant volume adjustment – 35
Constant volume lip seal – 38
Constant volume maintenance – 36
Cal Mode – 52
Calibration – 52, 58
Configuration – 47
CPU board – 59
CPU calibration – 60
Description – 47
Display board – 60
Engineering units – 54
Fault setup – 57
Front panel – 48
Hardware – 59
I/O board – 60
Keypad use – 47
Linearization – 55
Memory board – 60
Module range – 54
Operation – 47
Pressure – 47
Serial port setup – 59
Serial type selection – 60
Span value – 58
System lock – 53
Terminal block connections – 61
Unity gain – 58
Zero value – 58
R
Range change – 34
Regulator
Air control valve – 33
Precision gas – 33
RS-232 selection – 60
RS-485 selection – 60
S
Safety
Considerations – 1
Features – 15
Sample
Gas inlet – 22
Hazards – 5
Requirements – 9
Serial port setup
Transmitter – 59
Shutdown
Manual – 25
Specific gravity
Calibration – 45
Definition – 67
Option – 15
Specifications – 7
Analytical – 8
Features – 7
Hardware – 8
I/O – 9
Sample requirements – 9
Utility requirements – 9
Start up
Initial – 23
Normal – 24
STP
Definition – 67
U
Utility requirements – 9
W
WC
Definition – 67
Weekly maintenance – 27
Wobbe index
Definition – 67
Equation – 13
Mode – 12
Theory – 12
Y
Yearly maintenance – 27
T
Theory
Of operation – 12
Timer
Flame-out – 33
Transmitter
Alarm 1 setup – 56
Alarm 2 setup – 57
Alarm 3 setup – 57
Alarm relay acknowledge – 53
Flo-Cal User Guide
86
Index
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Flo-Cal User Guide
Thermo Fisher Scientific
81 Wyman Street
P.O. Box 9046
Waltham, Massachusetts 02454-9046
United States
www.thermofisher.com